DJ1R (SE50) af18e 125cc Stroker Build

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NZHonda
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DJ1R (SE50) af18e 125cc Stroker Build

Post by NZHonda » Mon Feb 10, 2020 3:18 am

Its about time I posted up this project. This has been in the works for YEARS as I collected the bits I needed. Originally I was going to put my stroker setup into a nifty50 but I went away from that. Basically the nifty50 is way to small for a man my size. Couple that with the fact I will be taking this cross country in New Zealand. Or rather across a mountain in winter.

The 1987 Honda DJ1R (SE50) used to belong to forum member paulpauly7. I bought it minus the engine. These are relatively rare here in NZ so this will be a cool unique build. This machine is in good condition for its age with the plastics etc all looking good. Good enough for what I want.

The AF18e engine is with paulpauy7 now. He is the 2 stroke wizard of Christchurch. The cases have been bored to accept the crank. The crank and cylinder kit is some cheap nasty Chinese thing I got off ebay about 8 years ago. Forgive me! I bought it before I new anything about scooter parts. All I saw was 125cc stroker and I wanted it! It really only has to last 500km (run in, tuning and the 250km to the west coast of NZ across the mountains for an event) before it blows up. If I get the 500km I will be happy. Paulpauly7 has ported it. Hes got all the bits but I am waiting on the genuine Honda bearings and seals to show up.

The plan.
Standard body work
Convert the oil tank into a fuel tank

AF18e 125cc with the tillotson carb from ScooterSwap
I wont list engine specs and internals until we are finished. It'll be a mix of cheap and expensive parts!

Malossi offset rear shock absorber

TrailTech Vapor dash board from ScooterSwap

NCY quick throttle

AF35 Dio ZX front end and headset

200mm disk brake

Genuine HYTEC dio alloys

Lots and lots of shiny bits.

Todays mission was to strip the front end and put the AF35 DIO ZX stem in. It was very straight forward. This forum was very helpful in preparing me for the job. Recently I bought a totally stuffed AF35 here in NZ so stripped it out for the steering stem and handle bars. The rest can go in the bin. I'm not even using the shocks and wheel etc. I have installed the aftermarket shocks (shiny!), Trial fitted the alloy wheels with the 200mm disk. There is still some fettling to do with bolt lengths, nice washers and shimming the axle spacing to spread the forks out more so that the disk bolts don't foul the shocks. Then its onto figuring out how to match all of the wiring because I'm going to use the AF35 Dio ZX headset with the yellow headlight.

The headset will get tidied up and painted white.

I want a clean JDM look. I like the look of the AF35 headset on the DJ1R. Having a disk brake is a must for the stroker engine.

Anyway, enjoy the pics. I hope you like the colour scheme. Factory blue/white with bright orange wheels.
Attachments
DJ1R 125cc Disk (1).JPG
DJ1R 125cc Disk (1).JPG (360.88 KiB) Viewed 98 times
Last edited by NZHonda on Mon Feb 10, 2020 3:25 am, edited 1 time in total.
Honda AF28 Dio ZX - Malossi 72cc
Honda DJ1R project

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Re: DJ1R (SE50) af18e 125cc Stroker Build

Post by NZHonda » Mon Feb 10, 2020 3:19 am

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Attachments
DJ1R 125cc Disk (2).JPG
The wrecked AF35 waiting its turn.
DJ1R 125cc Disk (2).JPG (343.01 KiB) Viewed 97 times
Honda AF28 Dio ZX - Malossi 72cc
Honda DJ1R project

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Re: DJ1R (SE50) af18e 125cc Stroker Build

Post by NZHonda » Mon Feb 10, 2020 3:19 am

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Attachments
DJ1R 125cc Disk (6).JPG
200mm brake kit takes up most of the wheel.
DJ1R 125cc Disk (6).JPG (316.21 KiB) Viewed 97 times
Honda AF28 Dio ZX - Malossi 72cc
Honda DJ1R project

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Re: DJ1R (SE50) af18e 125cc Stroker Build

Post by NZHonda » Mon Feb 10, 2020 3:20 am

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Attachments
DJ1R 125cc Disk (9).JPG
DJ1R 125cc Disk (9).JPG (308.11 KiB) Viewed 97 times
Honda AF28 Dio ZX - Malossi 72cc
Honda DJ1R project

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Re: DJ1R (SE50) af18e 125cc Stroker Build

Post by NZHonda » Mon Feb 10, 2020 3:20 am

.
Attachments
DJ1R 125cc Disk (10).JPG
DJ1R 125cc Disk (10).JPG (306.87 KiB) Viewed 97 times
Honda AF28 Dio ZX - Malossi 72cc
Honda DJ1R project

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Re: DJ1R (SE50) af18e 125cc Stroker Build

Post by NZHonda » Mon Feb 10, 2020 3:24 am

The steering stem bolted right in. I used the DJ1R bottom bearing cone. AF35 top nut. Greased both bearings and tightened it all up.

The stem is to wide for the factory plastics. I used a heat gun and a suitable wooden mallet thing I found in the shed to re-shape the panel. There is enough room but when I put the aftermarket shocks in the stick out above the steering stem. My cunning plan is to put it all together, use the heat gun on the outside of the panel and move the stem side to side to make enough room for itself. Should work out good.
Attachments
DJ1R 125cc Disk (3).JPG
DJ1R 125cc Disk (3).JPG (292.58 KiB) Viewed 96 times
Honda AF28 Dio ZX - Malossi 72cc
Honda DJ1R project

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NZHonda
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Re: DJ1R (SE50) af18e 125cc Stroker Build

Post by NZHonda » Mon Feb 10, 2020 3:24 am

.
Attachments
DJ1R 125cc Disk (5).JPG
DJ1R 125cc Disk (5).JPG (319.19 KiB) Viewed 96 times
Honda AF28 Dio ZX - Malossi 72cc
Honda DJ1R project

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Ben L.
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Re: DJ1R (SE50) af18e 125cc Stroker Build

Post by Ben L. » Mon Feb 10, 2020 6:38 am

Way cool! I’ll be following.

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