83 aero af05 swap

[Wingnutz]

hello im in the process of swapping an af05 into my 83 aero 50. i was just wondering a few things before i throw it all together.
1. will my stock air box work with this new setup? i will be using the stock af05 cylinder with a leovince sp3 exhaust. im sure i will have to make my own mounting bracket for the exhaust to mount to the frame but thats to be expected and i plan on up jetting to a 90 unless someone has a better recommendation .
2. am i going to be able to "plug and play" with the stock 83 cdi or will i need to purchase an af05 one?
3. ive read about some of the horror stories of the splines of the af05 cranks becoming stripped and it just so happens that the engine i acquired is worn about half way back onto the shaft (pics to follow once my buddy sends them to me lol) i was just wondering if i will be able to use the stock crank or if i should start shopping for another one?
4. i also bought a metro rear rim so i can run a tubeless i was just wondering if anyone knows how wide of a tire i can run so i can order one.
any suggestions are appreciated thanks!!!

[Wheelman-111]

Greetings:

Airbox probably won't fit. Leo pipe kit 4447 bolts to engine case, not frame. Body clearance unknown however.

3. Stripped crank may not be worth mounting.
4. 3.50 rear tire not worth the hassle needed to make room for it. 90/90 is hassle free. Deflate to mount, then re-inflate.

[Wingnutz]

finally got the picture of the crank splines. hopefully somebody will be able to tell whether or not i can use the engine in the current condition. if not are there any aftermarket cranks that are still available for af05 engines or do i have to try and find a stock crank?

[paulpauly7]

you could shorten the boss but you will loose take off speed big time.I would suggest finding a stock crank

[Wingnutz]

I know i might get some scrutiny for my new plan but here it goes..
I currently have a set of polini 7.3? gram rollers and a metro vari. i plan on ordering the longer polini 006 belt that wheelman speaks of and then just weld it on there before it gets completely stripped. i know its not a permanent fix but it will get me back on the road while i search for a crank or maybe even upgrade to an af16 in due time. Before i weld it together i just wanted to get some input on whether or not the 7ish gram rollers are going to be too heavy or should i maybe get down into the 5ish range since there will be no turning back at that point.
Another thing that i was thinking about doing was removing the 11.097:1 gears in favor of my '83 7.978:1 gears or is that too tall for not having a bbk installed yet or might not even fit? My theory behind the taller gears it will help me to keep up with my friends on longer stretches of road since they have bbks, larger carbs and exhausts on their aeros.

[Wheelman-111]

Greetings:

Stock on the Aero was 10 grams. 7.3-gram rollers may be in the ballpark, but no way to know before you weld and hard to remedy after. Maybe try once with some JB Weld just to determine if it's close? You may spin it soon, but at least you have a chance to re-think if it's way off.

Through a buying error I ended up with an '83 gearcase cover once. I still have it in fact. As I recall, the bearings were different sizes and possibly the centerlines different as well. May be more trouble than it's worth and 8:1 will be pretty tall for a stock bore. Compensate with higher vario speed, but power won't be there to utilize the full "overdrive' at the variator. In other words' it won't be any faster except downhill. Take-off will likely be excruciatingly slow.

[Wingnutz]

thanks again wheelman for all of your input!
So i might jb weld it first like you suggested to see how/if it performs (have to take one for the team and cruise around in the 30 degree weather) if the jb weld doesnt hold is there a possibility the drive face, variator or the belt will get damaged? also is it wise to go ahead and purchase the .006 belt if im running the metro variator with the 11:1 gears or wont it make that much of an impact if i use a stock belt?

[Wheelman-111]

Greetings:

If you shear what's left of the splines, you'll be pushing it home. Go no more thaan a half-mile out and turn. I don't see how the spun pulley can damage the belt or vario, but use the stock belt to test.

I don't quite recall the specs on the .006 belt.

[mmeadows]

hello are you swapping in the aero af05e engine or the spree af05 engine?

you referenced a variator so im going to assume you mean the af05e

i have swapped an af05e into my 84 aero ( same bike as the 83)

its an easy swap, i was able to do it with some simple wire connectors and a hammer, and im an idiot.

the only frustrating part of the swap is clearance. i had to cut some of my rear wheel plastic fender off. ( its under the seat anyways) and later modle engines ( mine was an 87 aero engine) have an anti-vibrarte thing that is suppose to slide in the hole of the tube frame. cut that s*** off, or beat it with a hammer, its not going to want to fit in the 83 tube frame.

what i did was i bought a rukus shock ( its new, its cheap, it fits) it is longer and will give you some extra room. even with the new shock it will always be a pain to take out the spark plug.

its a swap worth doing because it opens the door for parts.

[Wingnutz]

meadows i will be using a variated af05e engine that i found on a parts bike. The only downfall is the donor bike was a se50p and if that wasnt bad enough im pretty sure it happens to be the "iowa" version.. im not positive but i think the sticker on the gas tank happened to have the se50p-aa so i can only imagine that lack of performance that i have in store for me due to the fact that i have the stock 87 drive face that i have to use and the less than stellar gearing. luckily it didnt come with the restricted exhaust or carb but i did score some stock ones from an 85 aero parts bike until i collect the funding to further my build. does it matter if i use the rear shock from the 83 aero or the 87 elite they seem about the same size?? i know i had to modify the motor mount from my 83 aero to fit my af05 engine. but your saying you needed wire connectors to make it run the plugs dont just match up? i guess i should have suspected that..

But the way i look at it i am probably better off to start hunting down an af16 at this point rather than to buy the malossi bbk, leovince sp3 and an aftermarket carb and intake. i really do enjoy the whole idea of having to hunt down some of the parts for the af05's (makes the build more worthwhile to me once i get it on the road) but i think at this point looking into an af16 will become a cheaper option because i need more performance to keep up with the metrakit bbk,malossi wild lion, 21mm carb aero that is flipping me the bird as he pulls away from me
is that theright train of thought or am i missing something?

[mmeadows]

does it matter if i use the rear shock from the 83 aero or the 87 elite they seem about the same size?? i know i had to modify the motor mount from my 83 aero to fit my af05 engine. but your saying you needed wire connectors to make it run the plugs dont just match up? i guess i should have suspected that..

my garage use to also have the se50p living in it. the eliet shock, especially the 87 is way longer and i would use that one for sure.

as for the wiring, i dont remember exactly but i can run out and look, you basically just need to get a 2 to 1 connector, its coming off the alternator. again im hardly mechanically inclined and i was able to do it just messing around. so im sure you can too . you also need a need throttle cable. ( not a 83-84 cable )

But the way i look at it i am probably better off to start hunting down an af16 at this point rather than to buy the malossi bbk, leovince sp3 and an aftermarket carb and intake. i really do enjoy the whole idea of having to hunt down some of the parts for the af05's (makes the build more worthwhile to me once i get it on the road) but i think at this point looking into an af16 will become a cheaper option because i need more performance to keep up with the metrakit bbk,malossi wild lion, 21mm carb aero that is flipping me the bird as he pulls away from me
is that theright train of thought or am i missing something?

from what i understand its hard to find the af16 engines and they are $$$ but ive never really looked in to it. it just depends how far away you want to get from the original aero. you can buy rough 125s, running, clean title for 300 all day

[Wingnutz]

ok thanks meadows! well me and my buddy both have the day off tomorrow so were going to try and finish putting my top end together( just gotta pick up my circlips from the honda shop) then i should have all of the necessary components to see if this thing will work. i think we will first hook it up to his 85 aero since he has his engine dropped out anyway for a port job so we dont have to worry about the connectors yet i need to feel reassured that this thing runs before i get too far in.

As for finding an af16 i just recently saw mopedmark has 4 af16's for sale starting at 250 plus shipping but luckily hes only a couple hours away from where i go to college so that might work out in my favor.. compared to 180 for malossi bbk, 210 for leovince sp3 from daywot(which might be gone havnt seen them on ebay for a couple of days now) and either a jet kit or an aftermarket carb and manifold.

meadows i also see that you have the metro rim. i bought a rear met rim off ebay and the tire is pretty much junk i could probably ride it for a little while but im in the market for a new tire and i was just wondering if 90/90 is the widest tire that i can go with? i saw a 100/80 and 100/90 pirelli sl26 that caught my eye i know its not that much wider only probably like a quarter inch on each side but i want to stuff the widest tire in without having to grind much/any off my engine case. I didnt know what size tire you run with yours since we pretty much have the same setup going on.

Also if you could comment on what size rollers you think i should go with before i weld my drive face on i currently have polini 7.3g rollers and the restricted drive face with a metro variator.

[mmeadows]

Rollers are heavily dependent on the rider. IÔÇÖm 6"5 210lbs and I use 3 6's and 3 10's. And I notice a difference than if I use just 6 8 gram rollers. 7.3 arenÔÇÖt bad. Id weight until I ride the bike before I weld anything on. You might not be happy with takeoff/ top speed if you set it in stone now.

Imo 90/90 is the widest you can go. I have an unnoticeable bend in a rim that I got for free; a 90/90 will start to get a shinny melted tire spot from friction really fast.

If you get an af16 shipped for $250 IÔÇÖm jealous and I agree you should do it. (I have to remind myself of this ALOT so sorry if I sound redundant. if your just going for the most speed for your $. there are much better cc to $$ ratios out there when compared to these 50cc scooters.)

Have you considered a VT cycles bbk? Also you can get those pipes (Leo 4447) for $100 from sip scooters and feel cool getting a package from Germany. IÔÇÖm pretty sure that is where keoni gets his parts from. I also think he bought the last airsal kits

[Wingnutz]

yeah i tried to order a vtcycles bbk a couple months ago and i got no response but from what i read a lot of people dont get responses either so i didnt bother to look into it any further. i also looked into getting the sp3 from sip scooters but it was $110 plus $30 something for shipping and then someone told me that i had to pay a value added tax of 20% on top of all that for it to get shipped to me which discouraged me a bit. im not sure if thats true or not since i hadnt talked to anyone whos ordered anything from them. but if i could get those parts for a good deal then it would probably make me think twice about purchasing an af16


and i know that there are cheaper alternatives for getting more speed for your money but around where i live i like the idea of buying a $15 moped sticker for 3 years of riding rather than having to pay for insurance on a 80cc or larger since i dont know how some people work their way around that