'88 Elite DIO Swap

[zajaco]

In a few weeks I will have all the parts necessary to start my DIO build. I would like to thank everyone on this forum for contributing to my decisions. I have been lurking for sometime reading up on the ins and outs of these machines. Burnt_toast's build is where I got most of my ideas. My build will be pretty similar minus the stroker kit.

It started about 5 months ago when I came across a derelict '98 Elite SA50P. About the only thing not broken on the scooter was the DIO. It ran, but not well. In fact shortly after buying it and getting it running I convinced my wife to get on it. After taking it around the cul-de-sac she tagged my neighbors car... Scooter fund -$700




The 98's body wasn't salvageable and it didn't have a title so my search for another scooter began. I came across this little beauty in Iowa selling for only $350. The scooter is titled, it runs well and all the body panels are in decent shape. Not to mention it has the battery cover!! The white paint is going to have to go though. I'm thinking flat black all around.




The first step for me was getting all the parts together. Some are here now and the rest should arrive in the next week or so:
Corsa bore kit
Keli Vari
weight kit
8.4:1 gears
various gaskets, seals and bearings from Honda
PG long
1500 center spring
Keli clutch
CT intake
28MM OKO
jet kits
Uni filter
oil plug
throttle cable
vapor speed/tach/temp guage


After all that was decided I started to break the DIO down and clean gunk off of it.





I really hope someone else was watching when I took all this apart

[bigluelok]

nice build. i like the white.
what model is the white one?

[veedubh20]

that an elite LX50 and was made 1 yr old white color panels, cant get those complete panels

[zajaco]

Yep, veedubh20 nailed it. It's an 88 LX50 Elite. So, the white panels are pretty rare? I just can't get into them.

[veedubh20]

yes those are rare to get honda lx white panels.

s panels purple and yellow cannot get complete set.

Just red and black only.

[zajaco]

Go figure, I have the white panels and want a black scooter

[burnt_toast]

lookkinn good. keep it up

[zajaco]

So I got more of the go fast parts in. Still waiting on the PG long and oil plug from VT. I need to make another round of Honda purchases, I forgot some of the gaskets last time. Oh yeah, I need to find someone to press on the new gears too... So much to do


I got the Seat, side skirts and the old LX50 motor off the frame today. man, that thing was dirty. And yes, that is a walnut. It was wedged between the mount and the motor. Not sure what the previous owner was doing with his scooter.






In order to get the DIO to mount up to the LX50 frame I needed to swap the motor mounts too. The bolt mounting the DIO motor on is a bit bigger.


After a lot of heat and a gallon of penetrating lube the thing still wouldn't budge. Queue the cutoff wheel!


DIO mount and case mocked into place. I still need to move the DIO kick stand too. The LX50 had a home welded kick stand. It looked great...



Does anyone know if the LX50 brake cable will work with the DIO? The two cables I have are a bit different but it doesn't look different enough to matter.
Also, what do you guys running premix do with the oil tank? Do you leave it in there with just enough oil to keep the light off? Or, do you take it out and jumper the sensor wires?

[elitedio]

My light doesn't come on. I have my oil tank removed and the wires unplugged of course. apparently the sensor closes the connection when the oil gets low.

I am using my stock eliteE rear brake cable. I am running it without the spring. I also moved the bellcrank one notch.
Your project is shaping up nice!

[zajaco]

I have made some progress this week on the scoot. I got the kick stand moved over after hacking away at the home done weld job. If you don't know how to weld please learn on some scrap metal and not on an Elite's kickstand


I also got the new bearings installed, crank installed, boost port ported and the corsa kit installed. I meant to take a few pictures of the construction but it slipped my mind. The crank was giving me trouble going in but now it moves freely. Hopefully it fires up



Hacked up wiring fixed.


Question,
This is the gasket Honda makes for the intake. Why does it cover up some of the port? Will I get any more flow if I trim the gasket to just cover the edges of the opening?

[SpyderMike]

that CT mani should have came w/ a base gasket for the motor side

stock honda gasket is meant for stock honda intake reeds

[zajaco]

I got the motor complete and thrown back in the frame. I primed the carb a few times by kicking it over with out any power on. A little shot of starter fluid and one kick with power and she started right up. I'll post a video in a bit

[chrisxbro]

Lookin good big brother!!

Now you just need to head on over here so we can get my Spree up and runnin!!!

[zajaco]

We will get her running this weekend.

[zajaco]

Here is a short video of the beast. Sounds almost like a dirt bike.
http://www.youtube.com/watch?v=J6-TqYK0f8Y