How to change rings, piston, cylinder on a Honda dio scooter - Video

Accordingly, when installing, they are placed with the bevel upward. The bevel can be determined by eye, but usually a letter is engraved on the top side. Sometimes the top ring is chromed on the outside; its surface is lighter. We put on the rings.

I put the top one on through the top, the bottom one through the bottom. Don't forget to place a ring spring under the bottom ring. You put the central part of the ring on the piston, then put it on one by one.

Then spread the ends apart with your thumbnails and lower the ring down to the groove. Inside the grooves there are stopper pins that should fit into the slot of the ring on the right half of the pattern. Keep an eye on this when installing rings, and even more so when assembling the piston. The ring should dangle freely in the groove, completely fitting into it. If it moves slowly or doesn’t fit at all, then you either installed it upside down, or confused the top with the bottom, or the groove was poorly cleaned from carbon deposits, or you have an unexpected problem.

An unexpected problem - how to install Honda Dio standard rings. Mokikis are often ten years or more old, and piston rings are produced in our time.

In the set of a pair of rings I bought, the top one fit perfectly, and the bottom one turned out to be 1 thick. As it turned out, the problem is completely solvable. Take a flat glass surface or a very flat glass surface, place some sandpaper on it and start grinding the ring down to the required thickness. I don’t remember the grain of the skin, but it is noticeably larger than zero. Grinding layer 0. It is more convenient and correct to grind the ring not on sandpaper, but on a corundum block.

Moreover, you only need to grind one side - the one that will work. The ring is extremely hard and is very difficult to grind off. I adjusted it by rolling it in the piston groove and working out the places where it was stuck. At the time of writing this article, there are already three hundred models with new rings on how to install Honda Dio rings.

Before assembling the piston, practice using the removed piston to insert the piston into the cylinder and insert the retaining rings that hold the pin in the piston.

Before inserting the piston into the cylinder, lubricate everything with engine oil, align the ring cuts with the stoppers in the piston grooves, squeeze the rings with two fingers; they completely disappear into the piston grooves and insert the piston into the cylinder.

The piston will only fit perfectly along the axis of the cylinder; at the slightest misalignment it will jam. Accordingly, if it doesn’t climb, then you need to shake it slightly, catching the axle.

The piston should enter the cylinder with a slight force of about half a kilogram. Do not press, otherwise you will either break the rings or tear off the cylinder. If the rings are new, break in the engine.

Nice ride. Often, piston rings on a scooter become unusable after several years of use, since the bulk of small-displacement two-wheeled vehicles from near and far abroad have already seen a fair amount of use in their motorcycle life. As a rule, even those who like to repair everything with their own hands do not know how to properly replace piston rings, which ring to put first on the piston, which one second, how to correctly install the piston in the cylinder, why the piston and rings are marked with letters or arrows.

When repairing a cylinder-piston group, abbreviated as CGP, you can either completely replace the CGP or partially repair it by replacing worn parts, usually only rings. If the cylinder has significant wear or scratches on its internal walls, it is possible to either completely replace it or bore it for repair rings and the piston; as a result, the piston volume will increase, power will increase, and fuel consumption will increase.

A complete repair kit may consist of a cylinder, two rings and an optional bellows ring; its task is to spring the lower compression ring of the piston, the piston pin, to secure the piston to the crankshaft mechanism, and two piston pin retaining rings, the purpose of which is to lock the pin in the piston along with lever of the crankshaft mechanism. A small set may consist of piston rings, a piston and a pin with retaining rings. The minimum set may consist of standard or repair size rings.

As for the third piston ring in the kit, not all manufacturers make it and not all service stations install it, so if it’s missing, don’t worry too much, repairs are possible without it. Compression rings - also known as piston rings - for Honda scooters and scooters from other manufacturers may be the same, or they may differ, both in thickness and in the cross-section of the Honda Dio rings.

As a rule, the upper one is thinner than the lower one and has a different cross-section. If it is not possible to distinguish the upper ring from the lower one, then ring manufacturers indicate the first upper ring with the number 1, and the second lower ring with the number 2. Pay special attention, piston compression rings must be placed with the letter facing up, it must be present unless the rings have been machined turner. First, you need to put on the lower ring, then the upper one.

Do not bend the rings; they are very fragile; do not use brute force. On the piston in the grooves for the compression rings there are so-called locks, they look like a bump in the groove, the gap on the rings should fall under the lock, how to install Honda Dio rings there is a place for the edges of the ring under the lock.

Otherwise, it will not be possible to insert the piston with rings into the cylinder. It is also very important that the piston has an arrow on top, the inscription EX or other letters; this is an indicator that says that this side of the piston should be directed downwards towards the gas outlet window. While manipulating the cylinder-piston group, cover the crankcase, for example, with a rag, so that debris does not get into it and cause another breakdown.

When placing the piston and rings into the cylinder, lubricate the cylinder walls with oil, this will make the process easier and help avoid unnecessary scratches. Install the pin retaining ring on one side in advance so it will be easier. Check the condition of the pin bearing cage, check the connecting rod for flaws.

You need to tighten the cylinder bolts carefully without unnecessary force, crosswise, preferably using a torque wrench, of course. It is recommended to replace old gaskets with new ones, even if they were not torn when removing the cylinder; if the gaskets are intact, many do not install new gaskets.

How to install a piston on a scooter? This question is how to install Honda Dio rings for thousands of people who are faced with the problem of replacing a piston on a scooter or an entire piston group. Everyone knows that the piston plays an important role in the engine, so the agility of your two-wheeled friend depends on its technical condition. In this article we will try to provide detailed information on how to correctly install the piston, and also clearly show several types of pistons with different marks and designations.

To avoid getting into such a situation, before installing the piston into the engine, you must first inspect the piston itself and figure out what inscriptions or designations are on it. Markings on the piston of a four-stroke 4T scooter. Regardless of the engine size, be it 50 how to install rings on a Honda Dio Cube. It is with this mark that the piston should be installed to the intake manifold.

Markings on the piston of a two-stroke 2T scooter. On two-stroke scooters, there are markings on each scooter model - the piston is marked individually. The situation is also the same with piston manufacturers; some can put inscriptions on the piston, while others can simply put an arrow.

Below we will look at the most common designations on pistons. Next, let's look at an example of a tag on a Yamaha Jog scooter. Let's move on to the next example - the mark on the piston of the Suzuki AD scooter. To summarize the article, we will highlight an important clarification, namely regarding the marks on two-stroke pistons.

Insert the second retaining ring. Install a new gasket. Before installing the gasket, inspect the surface; if there is damage on it, repair it using sealant. Lubricate the rings with oil, being careful not to get any on the gasket. To avoid breakdowns and how to install Honda Dio piston rings, when installing the piston into the engine cylinder, we make a clamp from a strip of tin and compress the rings with it.

When compressing the rings with a clamp, make sure that the ring locks are strictly in the center of the locking pins in the piston grooves. After compressing the rings, twist the clamp slightly to the right - to the left, the rings should not rotate with the clamp. We fix the clamp using a bracket bent from the same strip of tin. Using a syringe, apply oil to the surface of the cylinder and spread it evenly over the entire surface. After lubricating the cylinder mirror, how to install rings on a Honda Dio, the plane of the crankcase and cylinder and install a new gasket, if necessary, seal the gasket.

Everything must be perfectly clean. We unscrew the spark plug and unscrew the nuts on how to install Honda Dio rings securing the cylinder head. Before unscrewing the nuts on the head, you need to thoroughly wash the junction of the cylinder and crankcase and the cylinder and head, since even if the engine was washed, a lot of sand still remained under the ribs, and when removing the cylinder it could easily get into the chamber.

We remove the head and cylinder; if it doesn’t work, you can pick it up with a pry bar. Also, if the old cylinder gaskets have become stuck and come off in pieces, you need to: So that the surface is even. If the aluminum gasket between the head and the cylinder is damaged, it can be cut out of the walls of several cola cans; it is advisable to remove the paint and varnish. Be sure to place a clean cloth between the connecting rod and the crankcase walls to prevent foreign objects from getting into the crankcase, which could cause damage to the crankshaft and piston group.

Remove the piston pin stopper and push out the pin. The finger sits very tightly in the piston, you have to apply a fair amount of pressure. While you are pushing the pin, make sure that there is no side load on the connecting rod. It may bend. It is better to do this operation by resting the piston sideways against some object, for example, against a wall through a piece of wooden beam - this will relieve the connecting rod and prevent it from being accidentally broken or bent.

How to change rings, piston, cylinder on a Honda dio scooter

In this case, by the way, it will be possible not to put pressure on the finger, but to carefully knock it out with a hammer through a mandrel of suitable diameter. We remove the piston. We take out the bearing separator.

Remove the old gasket. Assembly is carried out in reverse order. We install the separator, lubricate it with oil; it is best to use a medical syringe for this. The oil is the same that you pour into tank 2. Attention, the new piston, cylinder, piston pin... before installation, rinse in gasoline and blow with compressed air to remove the preservative. Install the rings.

Do this very carefully as the rings are easy to break. It is more convenient to put on the top one through the top, and the bottom one through the bottom. Don't forget to place a spacer ring under the bottom ring. Place the central part of the ring onto the piston, then put both ends on in turn. Then spread the ends apart with your thumbnails and lower the ring. How to install Honda Dio rings grooves.

Inside the grooves there are stopper pins that must fit into the slot of the ring. Keep an eye on this when installing rings, and even more so when assembling the piston. The ring should dangle freely in the groove, completely fitting into it. If it is difficult to walk or does not climb at all, then the rings are either placed upside down and are installed with the lettering facing up: An unexpected problem - a change in standards. Scooters are often ten years or more old, and piston rings are produced in our time.

how to install rings on honda dio

Sports CVTs

It's hard to imagine tuning a scooter without improving dynamics and increasing maximum speed. For a smoother change in the speed of the driven shaft, we suggest purchasing the following models of sports variators:

• variators HondaDioAF-18, HondaDioAF-27 / GY6 50CC (for a thin shaft of 12mm and 14mm, respectively) - suitable for tuning Honda Dio scooters, allowing to improve the maximum speed and dynamics of the vehicle;
• CVTs Yamaha Jog 3KJ, Yamaha Jog90/Stels – suitable for scooters of the corresponding model range; The pulley diameter has been increased by approximately 3mm, the shape of the grooves has been changed in such a way as to achieve maximum divergence, and weights of different weights are supplied in the kit for more precise adjustment.
• mechanical continuously variable transmission GY6 125-150CC - suitable for the engine of the specified model or Chinese analogues, provides an increase in the speed of the motorcycle and improves its dynamics.

Features of scooter tuning

So, tuning this popular vehicle may be needed in several cases

:

• you lack standard speed indicators, which do not exceed 60 kilometers per hour;
• to increase vehicle performance;
• to improve dynamics.

The entire process of tuning the muffler of a scooter model Honda Dio 18

and its other details consists of several successive stages.
Each of them involves carrying out certain operations with one or another part. Ideally, you should perform the following series of actions
:

• replace the muffler with a tuning resonant pipe, previously selected for the CPG;
• rebuild the transmission based on the characteristics of the tuning pipe;
• install a carburetor that has an optimal diffuser diameter;
• replace the conventional variator with a sports one (which will increase the overall efficiency of the transmission part and the acceleration response of the scooter);
• install a tuning CPG equipped with an expanded Sport class volume;
• carry out engine design using a tuning piston engine.

How I restored a Honda DIO AF28 moped Part 2

Last weekend I settled on painted wheels. Today I want to offer you a continuation of my story on the resuscitation of a purebred Japanese!

Now the most interesting thing for me is replacing the cylinder-piston group (CPG or simply a piston with a cylinder). The photo shows the condition of my piston and cylinder, which I removed from the moped. There was a decent amount of scuffing and wear in the cylinder, there was no gasket. Big snot from sealant. There are such notches on the cylinder that mother don’t worry.

I installed a new CPG, saved money and now I understand that it was in vain. The new piston installed without problems, but the compression was 6.5. This means I need to break it in properly and it will last for two seasons, at best.

After that, I replaced all the seals, fortunately they are sold as a set and only 6 or 7 pieces, I don’t remember. And the cost is 130 rubles. And, of course, after replacing the oil seals and cleaning out all the space under the variator and clutch covers, I replaced the rollers in the variator (mine were 8 grams, but they were not perfectly round in shape). I set it to 9 grams - this is the standard, but it turned out that this was too much and it would be better to set it to 7 grams on the contrary. I'll keep this in mind for the future.

Of course, I had to change the variator belt, as well as buy a full set of gaskets for this model. Some of them remained untouched, since I did not change the crankshaft bearings, but they will not be superfluous...

Time to paint the plastic. I painted the plastic with the same Montana that was left over from painting the wheels. Degrease well, then lightly coat paint. After drying, the layer is thicker, and the third is the final one.

But it looks a little strange, you must admit. A grown man can paint his moped in these bed colors. BUT the whole point is that further it will look quite aggressive, but for this it needs to be assembled and add zest to the appearance.

Namely, let's add BLOOD. More BLOOD. Zombies attacked our area and one got wrapped up in a wheel. To achieve this effect, you need to take a can of red paint and apply blots all over the body. I’m not very happy with the fat splashes, but with the blots it turned out great. As a result, the moped attracts attention and looks interesting, and anyone can do this.

What else can be improved?

You can also improve the Honda Dio AF 18 scooter by improving the piston group. First you need to check the compression, which should be between eight and ten atmospheres. If this indicator is not met, you will have to replace the rings or the CPG completely. In the first option, it is advisable to buy high-quality elements.

The process of polishing the cylinder head and the top of the piston will be useful. Getting rid of carbon deposits will increase the power of the moped. When performing this manipulation, you should remember that excessive force can lead to depressurization of the unit. New weights with greater weight can be installed on the scooter's variator. Before installation, it is advisable to run a grinding machine over the weight sockets, and then lubricate them with graphite lubricant (a thin layer).

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Today we will look at how to replace a standard piston Honda dio with a tuned Malossi using the example of a Honda dio af 27.

The design and position of the 27 dio engine is so simple that it can be repaired in the “field” conditions.

I will try to show how you can change the CPG without almost disassembling the scooter.

For all the work we will need two keys for 8 and 10.

First we remove the “toilet bowl”. To do this, unscrew all the bolts inside the trunk. We remove it, and in front of us is the engine itself:

The next step is to remove the exhaust pipe. To do this, unscrew all the bolts shown in the picture:

Next, we climb under the scooter and unscrew the bolts attached to the cylinder.

And this is what a fresh German Malossi Sport 72 cc CPG looks like. It also includes a few stickers so everyone knows what's "inside" you.

We will put all the bolts in this jar so that they don’t get lost.

And so, we removed the exhaust pipe:

Next, we look inside the scooter (through the trunk) and see that the casing still needs to be removed from the engine.

Remove the right side of the casing. At this point it is worth mentioning that the screws with which this half of the casing is screwed are located almost under the engine itself, and for ease of unscrewing, remove the bottom strip of the side plastic (plastic fastener near the taillight and two screws under the “legroom”), move the plastic slightly force in the direction of the rear light and remove it.

Next, remove the remaining part of the casing and unscrew the spark plug. The casing is secured with 2 bolts. Moreover, access to one (which is closer to the wheel) of them is very difficult.

Next, unscrew the 4 cylinder head bolts. This is what should happen: Now remove the cylinder itself. Just be careful there may be a gasket underneath that could tear.

Now let's start removing the piston. This is not a simple matter. First, put some cloth inside the crankcase (under the piston) so that nothing falls inside and gets wedged in the future. Now we take an awl or tweezers and remove the locking rings of the finger, which are located on the sides of the piston. One day, a retaining ring like this fell inside the crankcase. I thought nothing would happen, so I put it back together. I started the engine, and after 15 seconds, it jammed. It was very disappointing. So that's why we put a cloth inside. After we have removed both retaining rings, we take a suitable pin and, with light blows of a hammer, knock the pin out of the piston. Perhaps you can do without a hammer, just squeeze out your finger with your own efforts. This is what it should look like for you:

Next, we look inside the scooter (through the trunk) and see that the casing still needs to be removed from the engine.

Let's prepare a new piston for assembly: put rings on it. Let's align the protrusion on the piston with the cut of the rings so that they do not spin during operation.

We put the new piston in place. We insert the pin into it and into the connecting rod at the same time, and secure it on the sides with locking rings. We put a new gasket under the cylinder. And carefully install the cylinder, having previously lubricated it with the oil you use to fuel the scooter, so that the cylinder sits easier. Instead of the usual gasket to ensure tightness between the engine head and the cylinder, the kit comes with a rubber seal, we install it. Now we put the cylinder head in place and fasten it with 4 bolts:

Next, screw in the spark plug. Screw in the bolts with double-sided threads to secure the exhaust pipe. We replace the ring between the exhaust and the engine with a new one from the kit.

Put the casing back on and screw on the exhaust pipe:

We start the scooter from kickstarter. Leave the scooter idling until half the tank is used up. Next, we go through the run-in and enjoy. One caveat with a tuned CPG - we fill the scooter with only 95 gasoline.

Budget tuning using the example of Honda Dio AF-18

With this setting, the maximum speed will reach up to 60 km per hour. The difference from the basic setting is not big, but the acceleration and acceleration itself will be much greater. If the tuned Honda Dio is satisfied with these indicators, then the tuning of the scooter can be completed.

More advanced tuning If such indicators are not enough and you want your tuned Honda Dio to drive much faster and behave much more playfully for a minimal investment, then you need to treat tuning more carefully and modernize many elements of the scooter itself.

Tuning the piston group The engineers who worked on the Honda dio made it so that the dimensions of the crankcase will allow replacing the standard cylinder with a 39 mm piston and installing a unit with a 47 mm one. If a tuned Honda Dio undergoes such an operation and chooses a suitable piston and cylinder, the same Athena is ideal, then the engine capacity will increase to 74 cm cubic.

It is worth noting that the replaced engine is most likely made of aluminum, which means that the tuned Honda Dio does not have to be fancy with different cooling systems. The simplest thing is to simply clean the exhaust pipe.

Here you can do things differently. Someone advises to go over the tuned Honda Dio with a blowtorch; someone cut it at the seam, cleaned it and welded it back together. After this simple operation, the scooter will become more vigorous. So, that’s all about the exhaust for now, let’s move on to the piston. Everything is simple here if the compression is atm. It is not advisable to install Chinese piston rings for three hundred rubles; such savings can lead to replacing the entire CPG.

It is recommended to polish the Honda Dio cylinder head, as well as the top of the piston. No carbon deposits - more power

It would also be good to run a polishing machine over the windows. Attention!

In four-stroke engines, when cleaning the cylinder head, you should not forget that you cannot use sandpaper or a metal object to clean the valves at the point of their contact with the head body - this will lead to “depressurization”, and ultimately, to burnout of the valves. Well, a little about the Honda Dio CVT.

Just install new weights - a tuned Honda Dio, often heavier weights are installed at the factory. Before installing them, it would be a good idea to run a grinder along the weight paths and lubricate them with a thin layer of graphite grease. And, perhaps, the most important thing is the costs, or rather the almost absence of them, you can make the filter yourself, dig up the jet in your dad’s garage! If you are not preparing your scooter for serious racing, but simply need a tuned Honda Dio for maximum speed and traction, then I think it’s worth doing just that.

Spare parts and accessories for motorcycles

Based on the requirements of local market regulations, manufacturing companies constructively limit the speed of scooters in the 50cc class. The most common way is to limit the engine speed.

An additional wire has been introduced into the electrical circuit of the CDI electronic ignition control unit, which sets the “ceiling” for the frequency of spark formation on the spark plug electrodes. If you exclude the required wire from the CDI control circuit according to the documentation provided by the manufacturer, the engine speed will increase, as a result of which the maximum speed will increase.

The above is true for Yamaha brands European models up to. On the latest models from Yamaha and other companies, the rev limiter is included in the CDI logic without using a separate wire, so its removal is impossible without replacing the CDI unit with another so-called “sports” one. On some scooter models, in addition to the electronic limiter, the tuned Honda Dio also has a transmission limiter. The mechanical limiter uses a washer between the variator pulleys, which prevents the pulleys from moving all the way and making the variator belt work over a large radius.

To remove the washer correctly, you need special pullers and skills.

Increasing the piston volume to 76 cc on the Honda Dio scooter

Any scooter tuning is limited to certain limits and has a limit.
The limit is determined by the financial component (for the purchase of high-quality expensive parts), the capabilities of each specific engine (not all engines can be boosted equally well) and the need of the scooter owner (exactly why he is tuning the scooter). The last factor should be decisive, namely, why do you want to increase the dynamic and speed performance of your scooter? What goals are you trying to achieve and will it pay off in the future? Often scooterists engage in pseudo-tuning, not understanding the possible consequences for the equipment.

Scooter tuning and reducing engine life

It is important to understand that any boost to the engine definitely leads to a decrease in the reliability and overall service life of the engine components. Increasing volume and maximum speed inevitably leads to premature wear of the standard main bearings and crankshaft. When installing a piston with a volume of more than 62 cc, there is a need for additional adjustment of the oil and gasoline supply.

Increasing piston volume using the example of Honda Dio

One of the most common types of urban scooter tuning is increasing engine capacity. Let's consider the possibilities of such a boost using the example of a Honda Dio scooter with an AF18E engine. The manufacturer here provides a piston volume of 49.9 cubic centimeters, and the piston diameter is 39 mm.

List of models with the same engine:

• Honda Dio AF-18.
• Honda Tact AF-24.
• Honda Dio AF-27.
• Honda Dio AF-28.
• Honda Tact AF-30.
• Honda Tact AF-31.
• The piston also fits the Honda Lead AF-20, Cabina AF-33 and Broad AF-33 scooters.
• Honda DJ-1RR.
• Honda Dio SR AF-25.
• Honda Dio Fit AF -27.
• Honda Dio XR Baja

The dynamic and speed performance of these scooters are often inferior to those of similar equipment from Yamaha and Suzuki, however, the reliability of Honda engines has never been in doubt.

Volume matters

Most often, to increase engine capacity on these scooters, a 60cc or 65cc CPG is used. This volume allows you not to bother with major adjustments or replacing the carburetor, and the stock bearings and crankshaft are able to cope with slightly increased loads. In this case, the speed does not increase, since the engine speed remains the same, but only the dynamics increase. For many, this is enough for comfortable movement around the city. In this case, there is no need to change the cylinder head.

For more serious tuning enthusiasts, piston kits of 72cc or even 76cc (piston diameter 48 mm) are available. Just a few years ago, finding them was quite problematic, but now, with the increase in Chinese and Taiwanese factories of spare parts for scooters, there is no problem with this. You can buy one of these kits, for example, here: CPG 76cc Honda dio. The old cylinder head will no longer fit in this case, so usually all kits should also include a new head.

The process of replacing a stock piston with a larger volume kit

Installing a kit is no different from a standard piston replacement:

1. We place the scooter on the central support.
2. We remove the “toilet”.
3. Disconnect the carburetor along with the intake pipe and reed valve.
4. Unscrew the muffler and move it to the side.
5. Unscrew the bolts securing the cylinder blower casing and remove the casing to the side.
6. We unscrew the 4 bolts on the cylinder head, remove the cylinder, and replace the piston with a new one.
7. We install the new kit in reverse order with the gaskets from the kit.

Everything is simple here, now about the consequences:

Consequences of increasing piston volume on a scooter

• Just adjusting the carburetor, as was the case with the 60cc, will no longer be enough. The stock carburetor cannot fully deliver the required amount of fuel-air mixture due to its low flow rate. Ideally, you will need to replace the original carburetor with a model with a larger diffuser (for example, 18 mm).
• Naturally, the performance of the stock oil pump will not be enough. Adjusting oil pumps on Honda scooters, in this case, does not solve the problem. You will need to additionally add oil to gasoline at the rate of 1 to 25 (1 part oil to 25 parts gasoline) in the summer and 1 to 40 in the cold season. Converted to a liter of gasoline, we get, respectively, 40 grams of oil per 1 liter of gasoline in hot weather and 25 grams of oil per 1 liter of gasoline in the cold season. Ignoring this rule will inevitably lead to oil starvation of the engine and the corresponding consequences.
• Naturally, the service life of the stock main bearings and crankshaft is reduced.
• The maximum speed does not increase because the maximum engine speed is limited. To increase speed, you will need to either lengthen the gearbox or increase engine speed using a tuning switch. The second option with stock bearings and original crankshaft is not desirable, since increasing engine speed further reduces engine life.
• The dynamics increase significantly. You may have to reconsider the weight of the variator rollers.

This is such a budget tuning. Whether it is needed or not, everyone decides for themselves.

You can also read other articles on the topic:

Chassis

The big advantage of this scooter is the fact that its front suspension is made in the form of a telescopic fork. As for the rear suspension, it is a shock absorber, also equipped with a spring assembly. There are two brakes at once - both front and rear. In both cases, they are drum-type, which gives excellent control not only over the control of this scooter, but also over its braking

The result is a vehicle that definitely deserves the attention of those who are not yet ready to get on a motorcycle, but already want to ride on two wheels and gradually join the environment

Tuning Honda Tact, Dio scooter with AF24E engine

In this article I will tell you how, for a very reasonable amount of money, you can significantly increase the dynamics and power of a Honda Tact or Dio scooter equipped with an AF24E engine. By the way, tuning is a thing that knows no boundaries, rules and limits on the path to perfection. But the purpose of this article will not be to discuss tuning as such, but to talk about how you can significantly improve engine parameters while spending a minimum of effort and money.

For those who don't know, two-stroke engines, by their nature, are very responsive to increasing engine displacement. Unlike four-stroke engines. In four-stroke engines, engine power largely depends on the design and configuration of the cylinder head, but in two-stroke engines, the cylinder head does not have such a significant effect on engine power. Therefore, any, even small, increase in the volume of a two-stroke engine gives a significant increase in power over the entire engine speed range.

So, we go to the store and buy a piston with a volume of 72 cubic centimeters (47mm). I bought myself this one, it costs 1,300 rubles, but taking into account the discount, it cost me only 1,100 rubles.

For comparison: on the right is a piston (not original, the engine has already been removed from the farm, and quite “successfully”...) with a volume of 58 cubic centimeters (42mm), and on the left is a piston, which we will install with a volume of 72 cubic centimeters (47mm).

A few words about the piston: its manufacturer is Chinese a la noname, so you shouldn’t expect high service life and workmanship from it. There is no gasket for the cylinder head and cylinder in the box and they have to be purchased separately. There is no protective coating on the piston, and this is not good, although for a two-stroke engine the lack of a protective coating on the piston is not a critical point, but still...

The cylinder has a five-channel purge with a well-developed network of purge windows, which has a very positive effect on increasing power, especially in the high-speed zone.

The piston rings have clearly readable markings and their appearance inspires confidence. At the very least, it is difficult to make any complaints about the geometry and cleanliness of processing.

Now about the sad thing: it is not possible to install this piston engine without disassembling the engine and modifying the crankcase... But tuning, as we know, “requires sacrifices,” so if we want to significantly increase the power and dynamics of the scooter, then like it or not, we will have to disassemble the engine a little file the tides marked by arrows in the crank chamber.

The tides can be cut with a file, or they can be cut with a well-sharpened chisel. I cut it down with a chisel.

The second unpleasant point, and maybe not so much, is that the standard pump of the engine lubrication system will not be able to provide the proper level of lubrication for a piston of increased volume, and therefore with a larger working area. Therefore, when operating a scooter with a larger piston engine, you should add a little oil to the fuel tank of the scooter. In principle, this is where all the troubles associated with this piston engine end.

After modifying the crankcase, you should thoroughly wash all engine parts from any remaining metal shavings and abrasives, reassemble the engine in reverse order, and only then can you begin installation.

This piston is installed according to the same principles as any other piston for a two-stroke engine. The only difference, or most likely difficulty, is that there are no marks on the bottom of the piston that would allow the piston to be correctly positioned in the cylinder.

Therefore, when installing the piston on the crankshaft connecting rod, orient the piston so that the piston ring lock pins point strictly at the purge port located in the diametrically opposite direction from the exhaust port.

Now about the main thing

After installing a 72CC piston and proper running-in, the scooter significantly increases dynamics and power. Believe it or not, but with skillful handling of the throttle and at the same time playing along with the body, the scooter easily stands on the rear wheel while leaving Chinese garbage dumps of various kinds far behind...

Piston and rings on a HONDA DIO ZX mokika (AF28) Ring replacement procedure

I have not seen any information on the Internet about the design of the piston. During engine assembly, this caused both piston rings to break. I think people will be interested in familiarizing themselves with the design of the piston and not repeating my mistakes. As they say, from teapot to teapot. All dimensions refer to the Dio ZX engine.

Ring replacement procedure:

Remove the cylinder. Take a clean cloth and line the crankcase space around the connecting rod. Let the connecting rod stand vertically, resting on it. There is no such thing as perfect cleanliness, and the less dust that gets into the crankcase, the better. If even one grain of sand gets in, it can very seriously tear off the cylinder later.

The piston and connecting rod are connected with a finger (this is a metal rod, empty inside). It needs to be taken out. To do this, you need to remove one of the two locking rings. The easiest way is to pick it up with an awl and pick it out. It says on the Internet that they can be bent, but I doubt it.

In fact, proper snap rings have tendrils at the ends or a loop-like bend in the center. The antennae are brought together with thin pliers, and the loop is hooked with an awl towards the geometric axis of the piston pin - and the ring is easily removed. But there are also irregular rings - without antennae and loops, they have to be painfully picked out with a thick needle or a sharp awl.

After this, the finger is pushed out to the side from which the stopper was removed. The finger sits very tightly in the piston, you have to apply a fair amount of pressure. While you are pushing the pin, make sure that there is no side load on the connecting rod. It might break.

It is better to do this operation by resting the piston sideways against some object (for example, against a wall through a piece of wooden beam) - this will relieve the connecting rod and prevent it from being accidentally broken or bent. In this case, by the way, it will be possible not to put pressure on the finger, but to carefully knock it out with a hammer through a mandrel of suitable diameter.

Honda Dio AF 18: tuning

Since this modification is a budget option, it makes no sense to spend a lot of money on its modernization. However, inexpensive improvements can be made that will improve speed and some other indicators. First of all, you need to check the standard settings. After cleaning the exhaust pipe, air filter, adjusting the carburetor and variator, the owner will definitely be pleased with the results obtained.

To make the scooter more playful, you should remove the speed limiter. Buying a new filter, adjusting the jet for it and boring the accompanying elements makes it possible to slightly increase the speed parameters. You can additionally invigorate the two-wheeled “horse” by cleaning the exhaust pipe, heating it with a gas cutter, or sawing it in half, cleaning it and reconnecting it by welding.

Replacing the standard piston Honda dio with a tuned Malossi sport 72cc

For the entire operation we need only two keys: 8 and 10.

First, let’s remove the “toilet” and we will immediately have access to the engine.

We are dismantling the exhaust pipe. In my case, this is a tuned Leo Vince SP3 pipe.

And this is what a piston

Malossi 72cc kit. This kit also includes three stickers that can be used to cover the plastic parts of the scooter “so that everyone knows what they’re riding on.” It makes sense to stick stickers on unbroken plastic, so not now

Specifications

Main Specification

More advanced tuning

If such indicators are not enough and you want your Honda dio to go much faster and behave much more playfully for a minimal investment, then you need to treat tuning more carefully and modernize many elements of the scooter itself.

Piston group tuning

The engineers who worked on the Honda Dio made it so that the dimensions of the crankcase would allow replacing the standard cylinder with a 39 mm piston and installing a unit with a 47 mm one. If you carry out this operation and select a suitable piston and cylinder (the same Athena is ideal), then the engine volume will increase to 74 cm cubic. It's worth noting that the replacement engine is most likely made of aluminum, which means there's no need to go crazy with different cooling systems. The engine, although larger, produces more power and increases speed, does not require cooling.

Air filter tuning

The standard filter was not made and installed very well. The fact is that it gets dirty too often, which is why it needs to be constantly cleaned. In addition, it is installed in such a way that it is very difficult to get to. It is also not able to pass a sufficient amount of air when installing a new piston. Therefore it needs to be replaced.

You can install a regular car filter of small size. But you need to install it in the trunk. The scooter has a fairly sealed luggage compartment, which is why the filter simply does not have enough air. Therefore, you need to make a small and not entirely noticeable air intake. But you also shouldn’t forget that a lot of dust gets into it, so it’s worth making a coarse filter for the air intake.

To connect the filter and carburetor, you need to select the desired hose and simply fasten it tightly. But it's not that simple. Finding a suitable diameter is not difficult, but finding a hose that will not bend and create air obstructions is very difficult. You could choose a corrugated hose that does not bend when driving, but it creates a strong turbulence that blocks the air flow and thereby air entering the carburetor itself. To improve the performance of the engine and filter, you need to find a hose from the cooling system of the VAZ-2110. When the suspension oscillates, it does not bend and does not create any turbulence.

If everything is done correctly and a good filter is installed, the scooter will gain speed much faster, there will be enough air for the piston to operate, and you will not have to clean the new filter often. In addition, the noise from the filter is almost inaudible. The speed will increase by approximately 30-40%.

Muffler tuning

If you started tuning a Honda Dio and changed the piston performance, then you definitely need to change the muffler. The standard one is simply not able to cope with the air flow that is formed after upgrading or replacing the engine. In addition, the speed with such a muffler will not increase much. The scooter needs to replace the exhaust pipe! The most suitable model would be from Giannelli, but they have closed their production. But if you come across just such a model, then take it. It is worth noting that when installing this exhaust pipe, you need to carefully tune the engine and not over-lean the mixture. But if such an exhaust pipe was not found for the scooter, then Tecnigas is quite suitable. This option is something worse and louder, but also quite good.

Transmission tuning

Tuning a scooter will not be complete without altering the transmission. The fact is that the manufacturers did not take too much care in cooling the gearbox overheating, which can lead to rapid wear of the transmission itself. You can make a simple cooling system that will direct air flow to the transmission and to the gearbox itself. If you have good engineering skills, this is quite easy to do. Speed ​​will of course play a key role in cooling efficiency, but this does not mean that you need to drive too fast, take care of your life.

Tuning is an opportunity to increase the power of a motorcycle and give it an original appearance that emphasizes the individuality of the owner. On our website you can choose various spare parts for tuning mopeds and scooters:

• variators;
• sports mufflers;
• cylinder-piston group (enlarged);
• switches.

SjMakar › Blog › Honda DIO 35 ZX engine capital (Part 1)

after the events of January 2, after dreams were destroyed, and the financial issue became a lump in the throat, and in the near future there is only construction of housing purchased a few weeks before the accident (yes, for a couple of weeks I was generally the happiest person who had everything ...), so, based on the circumstances, dreaming about a new project or about any kind of reincarnation of this is out of the question... after a month in a cast, my head was swollen with thoughts, and my hands were itching to twirl something! since the property was purchased not far from the place of residence, it is impossible to get there on foot, as always, and by car is not rational, and not always convenient, then for such a case I got equipment last year...) On August 15, 2022 it was purchased here This

This is a Honda DIO 35 ZX...

in the summer when I assembled the Lada after painting and was somehow already in the mood for the finals, there wasn’t much to do there and it was somehow boring and I remembered more and more the school years and so, when all my free time was spent on a moped...) when I had Yamaha JOG Next Zone, when 10 hryvnia was enough to fill a full tank...) I drove 30,000 km on it, my dad didn’t even believe in such a mileage))) we rode wherever we wanted, constantly sat somewhere in the evenings, in general we spent our time in a completely different way as modern youth do while sitting in front of a monitor... this was my first vehicle with an internal combustion engine which I began to “tune”... increasing the volume, refining the transmission, complete painting, all sorts of lighting that were fashionable in those days...) and I parted with that moped for the sake of “casting” 15” for a Lada...)) the sale announcement is still in the archive on the sales website.)

Full tuning

In order to significantly improve engine performance, you will have to put in more effort and finances. So, first you need to purchase a piston system with a volume of 72 cubic centimeters, 47 millimeters in diameter. Its cost is approximately 1.5 thousand rubles. This price is often made in China, so you shouldn’t expect excellent quality. Such a piston has a short service life, and the kit does not include some parts, such as the cylinder head gasket and cylinder. You will have to buy them separately, since without this nothing will work. There should be five scavenge channels in the cylinder to significantly increase engine power and also soften the load on it at high speed. The wheels on the piston group should look reliable, well machined, and the inscriptions on them should be clear and easily legible. Any chips, cracks, or scratches should alert you; installing such parts can be dangerous.

Further, some difficulties arise, since without disassembling the engine, installing a piston is not possible. And also with such tuning, the supply of lubricant to the pistons begins to work poorly. This problem can be solved by adding oil to the fuel tank of the scooter during operation. In addition, the catheter should be modified. To do this, first disassemble the engine and slightly file the tides in the crank chamber with a file or chisel. Afterwards, treat the cuts and wash them so that no metal particles remain. Now you can begin installing the piston. A scooter piston system is installed just like any other, but it can be difficult to determine the correct side. The main thing in the installation is that the cylinder pins are directed towards the purge window. You can also process the edges of the vent windows so that their edges are smooth. After all these steps, you need to put the scooter back together and run it at low and medium speeds. Immediately after assembly, we do not recommend immediately accelerating and squeezing the maximum out of the vehicle; it is better to increase it gradually. After a few minutes of driving, you can already increase the speed to 70–75 km/h.

Replacing the cylinder-piston group on a Honda scooter

First, open the seat and remove the seat container (glove compartment).
Unscrew the four bolts securing the glove compartment and the mounting screws. We unscrew the oil plug and remove the glove compartment by simply lifting it up. We unscrew the bolts securing the cladding and carefully remove it, not forgetting to disconnect the contacts of the wires going to the brake light and turn indicators. We unscrew the bolts securing the cylinder airflow and securing the muffler to the cylinder. In this case, we do not completely unscrew the bolts securing the muffler to the cylinder. The bolts remain in the cylinder body, and the muffler hangs freely on them. Unscrew the lower bolt securing the muffler to the crankcase and remove the muffler. Special grooves are made in the attachment of the muffler to the cylinder, and when the muffler is moved from the bottom away from the wheel to the side, the upper part is released due to the grooves, and the muffler is freely removed. Remove the cylinder blower and the high-voltage wire cap from the spark plug.

Unscrew the four cylinder mounting bolts and remove them. Remove the cylinder head with gasket. The cylinder head should immediately be wiped of oil with a dry cloth, thereby preparing it for installation. By turning the crankshaft with a fan, we raise the piston to the top position so that debris does not get inside. The cylinder is held tightly to the gasket, so you need to tear it off its seat. To do this, lightly tap the cooling fins with a hammer. When the cylinder is torn off, carefully remove it.

So, we have the cylinder removed, and the piston on the connecting rod is sticking out of the crankcase. We take a clean cloth and plug the hole in the crankcase so that the retaining ring from the piston pin, which we will remove, does not accidentally fall out there. Remove the pin retaining ring. For convenience, remove the ring that is located not on the carburetor side, but on the muffler side. Use a screwdriver to pull the retaining ring out of the seat, and when it is removed, you need to remove the pin from the piston and connecting rod. To do this, take a screwdriver, and on the side of the piston where the stopper is not removed, we press the screwdriver against the finger. Lightly knock out the finger and remove the piston.

We immediately check the separator. This is a roller bearing that is installed in the connecting rod and a pin fits into it. We do this as follows: insert a finger into this bearing and, shaking it, check the play. If there is no play, then everything is fine; if there is play, it means the bearing is worn out and also needs to be replaced.

Thus, we removed the old cylinder-piston group. Now we need to install a new one. To do this we need a new cylinder and piston, new piston rings and a gasket between the cylinder and crankcase.

We install new piston rings on the piston. There are no difficulties here. Now you need to install the piston on the connecting rod. This is done in a strictly defined way, namely so that the piston ring stoppers are located in the direction opposite to the exhaust hole. The surface of the piston is marked on the side facing the exhaust port. This is either an arrow or the letters EX. We install the retaining ring of the pin into the new piston, again from the carburetor side.

We insert the finger into the piston until it protrudes from the inside where the connecting rod will be located. Place the piston on the connecting rod and place your finger in the connecting rod hole. Insert the finger all the way into the piston and install the retaining ring so that the finger is secured in the piston. The retaining ring should fit into its seat.

On the crankcase, we remove the remnants of the old gasket, clean it so that the surface is smooth, without any bumps from the old stuck gasket. Apply a thin layer of sealant to the mounting location on the new cylinder and install a new gasket there. We also coat the gasket installed on the new cylinder on the other side with a thin layer of sealant.

To put the cylinder on the piston, squeeze the piston rings with your fingers and, shaking slightly, insert the piston into the cylinder. The cylinder, where the piston enters it, is chamfered. But the rings will still need to be compressed. We do not twist the cylinder left and right, but rather rock it, helping the rings to enter it with the fingers of the other hand. As soon as the piston enters, we remove the fabric with which we covered the crankcase hole and insert the cylinder into the crankcase. Apply a very thin layer of sealant to the mounting positions of the cylinder and cylinder head. We install the aluminum gasket on the cylinder.

Equipment and safety

The modification in question is equipped with drum brakes; on more modern models, the front unit is of a disc type. Despite its effectiveness, it requires more careful maintenance since it is open and susceptible to contamination.

The Honda scooter is equipped with a spacious trunk located under the saddle of the unit. There are no pockets for tools and other small items in the front part. Due to its reliability, ease of maintenance and cost, this moped has remained popular for almost two decades. With proper care and timely replacement of consumables, it will serve the owner for a long time, without losing its main indicators.

Advantages

Despite the small engine capacity, the technology in question remains popular for a long time. Honda Dio AF18 scooters are optimal for traveling on asphalt. In urban conditions, this is an indispensable option for lovers of light motorcycles not intended for racing and high loads.

The front telescopic suspension unit has some rigidity and adjustable travel, which allows for good maneuvering on the roads. The wheels grip the surface well, allowing you to take almost any turns perfectly. Shock absorbers are very sensitive to potholes and uneven roads. Nevertheless, even if the elements fail, they can be replaced without problems in most specialized workshops. On dirt roads you will have to get used to the shaking, but at low speed it is quite possible to overcome such sections.