1986 Honda Aero 50 score!

[ScooterTweaks]

hey guys, i got this bike the day before christmas along with an 84 spree i am now working on. the aero needed some work but is a runner! the previous owner obviously wanted the bike to run so it appears they just kept using the battery to try to start the bike for long periods of time and ultimately the starter motor comm and brushes were toasted and basically welded together. i took the motor all apart and cleaned the comm with some cleaner then went at it with some 800 grit. the brushes were actually stuck in the plastic housings. once broken loose i cleaned them off with some 1000 grit and sprayed them down with some cleaner. after putting it back together i dunked and ran it in some distilled water with a direct connect to a battery for 2 minutes and then sprayed some cleaner in there and blew air inside to get all the water out. the electric start now works just like new! so smooth and quiet. words cant explain my joy in this little victory!

before the electric start, i was kicking the bike over with a fresh battery, had great spark, good fuel flow and oil but no fire.... well, the bike had been sitting for a while so i filled the crank case, fuel lines, carb, and carb bowl with marvel mistery oil hoping to clean a lot of things up. it sat this way for a few days while i went over some other things. after pulling the trans apart i found that the variator side crank seal had blown out... so i pushed it back in after a good cleaning and it fit nice and snug. no leaks as of right now. i then turned my attention to the final drive gears. after draining the old fluid i ran some cleaner through it then flushed it, filled with some oil spun it all around, drained it and filled with good honda oil. ready to go! a few light kick starts with the exhaust pulled off cleared the crank case of all the marvel oil and i drained the carb as well. filling the tank with fresh gas, priming the carb, installing a new spark plug and putting the trans all back together and she started with the electric stat on the second try.


so far i have not tackled the body and front blinker. it just needs a good cleaning and tires right now. the brakes are pretty amazing really.

needs a rear light lens





side storage door, lock, weather stripping, and door support cable are all in good shape

super low miles

i found the original owners manual in the glove box

seats in ok shape, prob wont do anything to it for some time

sitting lined up with the 87 elite and 85 aero

sitting at the shop amongst so many scooters... it looks so tiny



plans for this bike are to repaint honda championship racing white with pearl and custom blue/white vinyl aero stickers on side panels, built engine and trans with custom intake manifold and 17.5mm carb, custom exhaust, and better bigger tires. i will also be converting the blinkers to dual element housings and bulbs. the lights will be on all the time with 7.3 watts then blink with 25 watts. cant wait, should look amazing. it is running now and hitting 35-40 so i am happy. as i work on the blinkers i will take pics and make a small tutorial of the process.

hope you all enjoy!

ScooterSteve

[sanjuro]

Nice score Steve!!!

[ScooterTweaks]

update:

located some factory front signal lenses for CHEEEEEEEEEEEEEEEEAP! anyone interested let me know and i can get some more. also scored a new front left blinker housing, no lens, on ebay for cheap. i have the j spec rear blinker and tail light on the way but still waiting.... i have a neat idea that i will be working on towards the end of the week and want to share it with you guys. should look really really good once finished.

i emailed a buddy the other day who does custom paint and body to see when he can tackle my paint scheme on this bike. i think i have decided to stick with the white but particularly acura integra type r white with light pearl overlay. then, gun metal wheels to finish off the look. i also contacted another buddy who runs underground graphics in houston about some custom decals for this one after the paint is finished.

later this week i should have this one all cleaned up and hope to have my idea on this one finished so i can post some pics and a vid.

[ScooterTweaks]

!!!OMG!!! Been working on the bike guys. I think you will like what I have done. But, this is quite interesting... I just picked up an 87 SE50 for a customer and when cleaning it up and adjusting the front blinkers noticed that they are the exact same as the Aero 50!!! I thought, "no way???) but it bolted right on. So, I found a few lenses and whole assemblies on ebay and had to purchase them. I have seen them before and needed new front blinkers but never knew they fit!

When the parts arrive I will do a comparison etc. and show what work I have been doing.

ScooterSteve

[ScooterTweaks]

Alright so here is a little of what I have been up to:

I am turning the blinkers to running lights with blinkers. I have a "few" pics of my work so far.

For the rear you start by taking off the rack, side panels, and blinker lenses.







Dont forget this 10mm bolt inside the storage box.





After you remove the screw holding the lens on, be sure you slide the lens inward to release this tab.



Then remove this screw from the back side to release the inner reflector.





The light socket is pressed in and has a lip that will need to be either ground down with a dremel tool or do like I did, since my dremel is dead, and use some pliers to bend and grab the socket loose till it releases easily without damaging the plastic.





Then you will need your dual tab light socket from Autozone. It is a DORMAN 85803 socket. You will need to modify it just a bit.



Grab a file and ruff up a portion of the socket housing to accept solder and a ground wire. Below is an example:









I also recommend a quick solder bead on the contact tabs to keep things together. The socket seems a bit cheap to me. Soldered and not.



I pre bent the tabs using a 5/8 spark plug socket to evenly prepare them for fitment. You can do this however you like, this was my choice.



Once fit from the back side, press the tabs till you have a solid grip. I used a flat head driver, then a vise "c" clamp. Worked for me!





Next up, wiring. Locate your original wiring. Connect the green to your new ground and blue to your "bright" blinker wire. The last wire is the constant on "low" output which will be connected to a switched + output.











Here I brought the constant + wire from the right blinker to the left blinker and made a connection.





Now add your bulbs, also from Autozone, dual element bulbs with low watt, 1157. I chose 12.8/27.6 watt because it's the lowest I found.



This is one side lit up, no blinker, just to test and show it working. I will shoot a video once its completed.



The front is basically the same with only a few changes: the socket has a lip that runs through the housing and reflector. Be sure not to damage your reflector when removing this socket.









Next you will be bending the tabs into the housing, not the reflector.





Once the socket is fitted, insert your reflector and bulb. Now install your new lenses! If you have them. Scored them cheap on ebay.









That is it for now. I will be running a new constant/switch + wire to a fused block for the running lights and my storage lights I will be installing. Hope you all enjoy and that maybe this helps anyone else looking to do this easy mod.

Thanks

[z50r-ghost]

Wow, ScooterTweaks, THAT was a great tutorial on the conversion! Nice work man, and super-nice Aero. Looking forward to your progress, bro-

Thanks for taking your time to teach the dual-filament idea.

Jon

[mousewheels]

Yes sir - nice work -- Thanks!

[micbergsma]

woohoo!!
looking at the pictures, I did something like that on my reflex and burgman before... fun project

[Dio89Elite]

wow ScooterSteve awesome work!
I love the tutorial. thanks for sharing!
can't wait to see what's next!