'92 Dio SR Build

[Hksdio]

Ok i shall order the plug. Can anyone who has one show me how they have braced the plug?

[MrJumps]

A quarter works, well I guess a coin works. Wasers work the main objective is getting the plug in tight. They can pop back out it is rare they just really need to be held in.

[MrJumps]

Im like right behind you build wise, I need to get my bore and transmissiona dn pipe. We will pretty much have identical builds. Except mine will be on a spree.

[Hksdio]

Yeah i need to remove the gears this week and get the new ones pressed in.

Little update but an important one, since the dio has most likely sat outside for its entire life its badly faded.

After some research i ordered a product called Wipe New and here is the result.

[sanjuro]

That's amazing how the product worked.

...and nice bokeh on the cylinder shot.

[MrJumps]

Looks good! Hopefully you will be up and running in no time.

[Hksdio]

Question, what is the best way to drain the tank? I will be running premix with an oil plug and the fuel in the tank has probably been in there for a year.

[MrJumps]

I take the hose that goes to the carb and put it in a container to catch the gas and suck on the vacume line to open the flow then slide my finger in my mouth and over the end of the hose to hold suction until it quits flowing and pour straight gas into it to flush it out a bit then reattach both hoses and fill up with premix and continuethat build.

[Ultraliner]

Question, what is the best way to drain the tank? I will be running premix with an oil plug and the fuel in the tank has probably been in there for a year.

I lifted the floor panels on mine tonight, pulled the tank and drained it right out. 8 bolts and a couple of hoseclamps later and it was out in no time

You gotta sweet looking build there mate, looking forward to hear how she runs!

[Hksdio]

No new updates, just awaiting parts.

Question, does anyone have a diy regarding the gear replacement procedure? The more photos the better.

Thanks.

[Wheelman-111]

Greetings:

There are some in Tech sections. The parts diagrams from parts vendors tells what goes where, and the Service Manual has a pretty good step-by-step. Most aftermarket countershafts are a hair too long. You must order a second thin metal thrust washer to replace the thicker stock plastic washer or the countershaft will bind when you tighten up the case cover. A heavy press is needed for removal of gear #4 from the axle. Put the new one on domed side out. Keep track of which cover bolt goes where; there'a at least 3 different lengths.

[MrJumps]

Besides the gear pressing I was able to pull the case apart and put it back together in minutes. I can tell you one trick get someone to just keep turning the shaft wuth there hands as you place the panal back on. Its quiet easy but takes a little time. I can text you pictures if the guide isnt good enough

[Hksdio]

thanks for the gear advice guys, very helpful.

so a few things have arrived.



it's a basic YSS coilover, i ordered white but they sent black, i don't think im going to bother exchanging.



complete with adorable c spanner which is about 1/3 the size of my car one!



if you follow my thread you would have learnt not to pry things, you can break the stator.

new stator arrived and installed, bonus is that the engine is so basic i now have a big chunk of new wiring.



so here how the "powerplant" is sitting at the moment.



next up is to crimp on some bullet connectors for the japanese taillight to match my main harness.



dont mind the crack on the lens, i picked up a new lens set for $10 from webike.



the plug that will be chopped for bullet connectors!

[MrJumps]

Can I borrow that c spanner hahahah!

nah, Nice build so far, it is looking good.

[Hksdio]

order arrived from webike, nothing exciting but a few needed items.

having been questioning my ebay purchased drive belt i ordered a kn planning one which is fits perfectly.



the mirrors are really rusted so i picked up a new pair.



ordered front and rear shoes, as far as im aware these are universal for both axles.

notice the wear on the old one vs new.



also decided to grab a kn planning trans oil plug since it was so cheap.