Dio disc brake front on Elite frame

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bonesv
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Dio disc brake front on Elite frame

Post by bonesv » Sun Mar 08, 2015 12:34 am

This post will show you one way to fabricate the af16 elite frame to run the af28/af35 Honda Dio headset, handlebars and disc brake setup using the metropolitan triple tree.
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Cut Here ^ ^ ^ ^ and Here v v v v
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Then weld it......
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Honda Elite SR
Honda Dio-Elite SR
Honda Elite LX
Pineapplegti wrote:Ruckus mods should never carry over to vintage scooters......it just isn't kosher.

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Re: Dio disc brake front on Elite frame

Post by bonesv » Sun Mar 08, 2015 12:34 am

Then cut the top for correct size of metro stem and install bearing cup.
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Before moving on, the metro uses a larger bearing on the bottom than the elite, so remove the lower bearing race from the metro stem carefully and replace it with a new (you have to order one from honda) elite lower stem race. It's a press fit so make sure it's all the way on. Next, remove some of the material from the stops on the metro stem to suit your steering desires.
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With the use of the af28 handlebars, and cutting the neck off of the elite, you will lose the use of the key switch/locking mechanisim. Yes, to do this you must source a complete Dio-from-Japan-front-end. Always liked the look so I did some bidding and not so bad. Stay tuned for more, it's almost finished!
Last edited by bonesv on Sun Mar 08, 2015 1:59 am, edited 2 times in total.
Honda Elite SR
Honda Dio-Elite SR
Honda Elite LX
Pineapplegti wrote:Ruckus mods should never carry over to vintage scooters......it just isn't kosher.

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Re: Dio disc brake front on Elite frame

Post by bonesv » Sun Mar 08, 2015 12:35 am

Assemble parts...
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Add the fender to estimate clearance
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Use heat gun to make clearance for turning radius....then install inner floor /glovebox to check fitment. Mocking-up the parts is crucial for correct look/fit. Install headset for fitment.
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Stay tuned for more.....
Last edited by bonesv on Sun Mar 08, 2015 1:57 am, edited 1 time in total.
Honda Elite SR
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Pineapplegti wrote:Ruckus mods should never carry over to vintage scooters......it just isn't kosher.

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Re: Dio disc brake front on Elite frame

Post by bonesv » Sun Mar 08, 2015 12:35 am

Once everything is to your liking, you must first swap-out the plug-ins for the speedometer to fit the elite. Just cut and splice....easy. Then, prepare to install the dash, throttle cable, disc brake reservoir/lever, rear brake cable......
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Keep in mind, this is just a mock-up for a customer. I would never do this on my own scooter!!! Well, maybe......ooops! Daylight savings time just kicked in, I better get some sleep...
Last edited by bonesv on Sun Mar 08, 2015 3:11 am, edited 2 times in total.
Honda Elite SR
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Pineapplegti wrote:Ruckus mods should never carry over to vintage scooters......it just isn't kosher.

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Re: Dio disc brake front on Elite frame

Post by bonesv » Sun Mar 08, 2015 12:36 am

Putting it together..... install the Dio legs.....
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finish up headset and dash......install Dio wheels/brakes and front/rear plastics
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Now as you know, we must test ride it into the sunset!
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Last edited by bonesv on Mon Mar 09, 2015 12:31 am, edited 1 time in total.
Honda Elite SR
Honda Dio-Elite SR
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Pineapplegti wrote:Ruckus mods should never carry over to vintage scooters......it just isn't kosher.

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Re: Dio disc brake front on Elite frame

Post by bonesv » Sun Mar 08, 2015 12:37 am

WOW! What a nice ride with this front end! I'm pleased with the handling and ride. Maybe some shorter legs would help the elite's profile but all-in-all, the feel of the road is great!
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I just may do this to my own ride some day! Going to give him a bid to paint up the gray faded plastic and trim, etc... Definitely liking the look of this scooter now! I will get some more pics when it's finished complete. Thanks for looking and if you need any info I may be able to give, just pm me.
Last edited by bonesv on Mon Mar 09, 2015 12:43 am, edited 1 time in total.
Honda Elite SR
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Pineapplegti wrote:Ruckus mods should never carry over to vintage scooters......it just isn't kosher.

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Re: Dio disc brake front on Elite frame

Post by bonesv » Sun Mar 08, 2015 1:18 am

So I have re-painted the faded gray plastics with some nice bumper coating from the local auto parts store, and got some cheap but cool looking mirrors to help it out, then re-covered his seat for him.
Go ahead, shoot us some comments.....I already know it would look better if it was slammed but he don't want that.
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Last edited by bonesv on Sat Mar 21, 2015 12:55 am, edited 1 time in total.
Honda Elite SR
Honda Dio-Elite SR
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Pineapplegti wrote:Ruckus mods should never carry over to vintage scooters......it just isn't kosher.

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Re: Dio disc brake front on Elite frame

Post by bonesv » Mon Mar 09, 2015 12:52 am

I had seen some pics of guys in Hawaii with the Dio headset on an elite and thus it inspired me to try this. I also want to thank Paul and Brandon for their contributions to my imagination. I couldn't have thought of this all on my own....But actually it was way easier than I had first thought.
Also, many thanks to hondaspree.net for this awesome forum and the experience of the members here.
Bones
Honda Elite SR
Honda Dio-Elite SR
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Pineapplegti wrote:Ruckus mods should never carry over to vintage scooters......it just isn't kosher.

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Re: Dio disc brake front on Elite frame

Post by swimmingfree » Mon Mar 09, 2015 8:51 am

that is slick way of doing it ...
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Re: Dio disc brake front on Elite frame

Post by kauaianman » Mon Mar 09, 2015 10:54 pm

bonesv wrote:Then cut the top for correct size of metro stem and install bearing cup.
IMAG0850 - Copy.jpg
Before moving on, the metro uses a larger bearing on the bottom than the elite, so remove the lower bearing race from the metro stem carefully and replace it with a new (you have to order one from honda) elite lower stem race. It's a press fit so make sure it's all the way on. Next, remove some of the material from the stops on the metro stem to suit your steering desires.
IMAG0859 copy.jpg
IMAG0862 copy.jpg
With the use of the af28 handlebars, and cutting the neck off of the elite, you will lose the use of the key switch/locking mechanisim. Yes, to do this you must source a complete Dio-from-Japan-front-end. Always liked the look so I did some bidding and not so bad. Stay tuned for more, it's almost finished!

Bidding? what site did you find that superdio headset and handlebar?
:happy:

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Re: Dio disc brake front on Elite frame

Post by bonesv » Mon Mar 09, 2015 11:36 pm

kauaianman wrote:
Bidding? what site did you find that superdio headset and handlebar?
:happy:
Ahhh. You hear very well......Got them from a member here on the forum about a year ago.
Are you looking for one?
Honda Elite SR
Honda Dio-Elite SR
Honda Elite LX
Pineapplegti wrote:Ruckus mods should never carry over to vintage scooters......it just isn't kosher.

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Re: Dio disc brake front on Elite frame

Post by bonesv » Sat Mar 21, 2015 12:59 am

I have added some more pics of the finished job. Scroll back from here a bit.
Honda Elite SR
Honda Dio-Elite SR
Honda Elite LX
Pineapplegti wrote:Ruckus mods should never carry over to vintage scooters......it just isn't kosher.

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Re: Dio disc brake front on Elite frame

Post by Rip_City_Spree » Sat Mar 21, 2015 2:10 am

Sweet looking elite.
01 Elite SR
polini corsa
Polini 26mm Carb
Naraku intake
Naraku sport variator
Currently 5g rollers
zx trans
Arrow
red contra with yellow clutch springs.
RIP CITY
RIP NO MERCY KERSEY

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Re: Dio disc brake front on Elite frame

Post by 1man8scoots » Sat Mar 21, 2015 9:18 am

I need to drop off one of my elites to you, if I started riding it now to you I'll be there by summer. Nice fab work bones!

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Re: Dio disc brake front on Elite frame

Post by Mini_Stroker305 » Tue Mar 24, 2015 11:35 am

Nice bike love the dio headset and front disc brakes :love:
96 Yamaha Jog Next Zone CY50
72cc Polini Evo 2
Ruima 41.4 Teflon ministroke
Yasuni C16
24mm Polini pwk
Malossi 8:1 Primary Gears
Malossi VL14 Reeds
Polini 360 Mani
Jaingwayne transmission
Michelin S1 tires 90/90/10
Hoca Racing Fan/Alternator kit

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