My 2001 elite 50 build-up

[aerorob]

couple updates, got the scooter ready for the big bore kit.
first kit had a couple issues with it from shipping, so i had to exchange it, but am still excited for the swap. got my stock clutch springs in and 8 g rollers in it. should be good for nice and low rpms so i can ride it around for break in before summer!

[aerorob]

ok, so rumia 48mm big bore came today from burnts scoot shop in excellent condition.
tommrrow i am throwing together the kickstart that i got for my aero so i have a scooter to ride, then, diving into the big bore install.

any last tips, tricks, words from those who have done it before?
things i absolutely have to do right in order for this to work without too many hitches?

[Wheelman-111]

Greetings:

First, take a deep breath. You can do this.

Second, take your time making sure all the gasket surfaces are squeaky-clean. The smallest speck or gouge virtually guarantees a leak. The cylinder is new, but the mating area on the crankcase has to be just as clean. Be careful with gasket remover scrapers, they can gouge the soft Al. Flat and square is good. Personally, I like to coat the base gasket on both sides with high-temp grease. It makes clean-up easier next time, and helps keep things aligned during assembly. It also starts the absorption process that swells the gasket into a better barrier against leaks.

Slather everything that's metal and spins or slides with a generous coat of GN-2. Use a little paintbrush.

Squeeze the rings one at a time into the chamfer of the cylinder, keeping the piston rigidly square in the bore. Make sure the little pins in the ring lands are centered in the ring gap.

Have a decent torque wrench. Cast Al threads strip easily. Follow the Service Manual specs, tightening down the headbolts in a criss-cross pattern. Lightly oil the threads and the heads of the bolts where they meet the cylinder head. 11 pounds plus 1 for good luck!

[martynkim]

Rob, where did you get your kit from?

[evilone]

Rob, where did you get your kit from?

http://scootspecs.wordpress.com/honda-dioelite-s-50cc/

[aerorob]

Yup, from scootspecs. I'm. Installing today. Ill try to remember my camera!

[tw39515]

Rob what was wrong with the kit i have 2 here waitng to install. havent even opened the boxes.

[aerorob]

Nothing is wrong with the kit. The first kit that got sent to me looked like an ovelrly agressive mailman had his way with it, but I returned it and burnt sent me annother in perfect condition.

[tw39515]

also i noticed this kit comes with three rings. the other kits ive installed didnt have the compression ring.

[tw39515]

cool, good luck with the install

[aerorob]

Yes, it sort of has three... it has a expansion ring that goes in the bottom groove under the actual piston ring.

[tw39515]

does any one have advice on wether or not to use the expansion ring.

[evilone]

If it's hexagon shaped it's the expander ring, go ahead and use it, it goes in lower groove before installing the lower ring.

[evilone]

Whoops, i see aerorob already told you where it goes.

[aerorob]

ok..
lots of progress! all this happened in about 20 mins. (alot more simple than a head gasket on a 22re)