Help: Honda DJ1R (SE50) with Dio front end

[NZHonda]

Hi everyone,

I'm about to start a new Honda project. Cool Honda DJ1RR that is going to get my AF18e 125cc stroker engine. I want to put a disk brake JDM ZX Dio front end onto it.

Has anyone put a Dio front end into a DJ1RR? Or changed it to something similar? Hoping to put a complete front end in and use the Dio headset.

I will be having a go in a few weeks so will report back. If anyone has had a ago at the DJ1 front end then tell me your experiences.

[bonesv]

I have heard the oem dio stem would work on the af12(DJ-1) or af19(DJ-1RR) frame. I have not done this myself but you can ask around

[NZHonda]

Well after a lot of googling. I have found out that my JDM 1987 Honda DJ1RR is a 1987 Honda Elite S/R SE50 in the USA. That makes searching the forum a lot easier. From these threads it looks like the JDM Dio ZX triple tree and front end that I have should bolt straight in. There's nothing else to do but pull it apart and give it a go I guess. I would like to have a JDM Dio headset with the yellow light. I'll have to see if this is possible and will work.

Should be fun.

http://www.motorscooterguide.net/Honda/ ... eSE50.html

viewtopic.php?f=4&t=17971&p=152308&hili ... ke#p152308

viewtopic.php?f=4&t=19555&p=180193&hili ... es#p180193

[bonesv]

Yes when you refer to the zx stem, you need the af28 or af35 stem. The af27 & af34 stem is only for drum brake. The dio headset will bolt right on as long as you use the matching handlebars etc.

[bonesv]

This company is good seller I have purchased from many times. https://www.ebay.com/itm/HONDA-AF28-Sup ... SwTgJctSBd

[NZHonda]

Okay that's interesting about the stems. I have in the past used a standard drum brake stem and put disk brake front suspension legs in and it all seemed to work. Thanks for the link.

What is the difference between the AF27 drum stem and the AF28 disk stem?

[bonesv]

Width is the difference. It isn’t much but the disc brake wheel with correct spacers and speedometer gear will need a tad more width between the forks than the drum setup. I suppose you could somehow make it fit.

[harleyracer59]

Yes when you refer to the zx stem, you need the af28 or af35 stem. The af27 & af34 stem is only for drum brake. The dio headset will bolt right on as long as you use the matching handlebars etc.

this makes sense. I have an af34 stem that was too narrow for my zx disk wheel. I then bought an af35 stem that was the correct width for the disk front wheel and axel. af 34 will not fit a disk wheel at all. even with different axel spacers. caliper disk alignment puts the tire into the opposite fork leg. also both stems are the same length and both fit an 87 se50 elite/ dj1 or dj1r (af12). I was always under the assumption that the dj1rr were af19's, is yours for sure a dj1rr? does it for sure have an af05e engine? or is it a dio?
from what ive found, metropolitans have the correct width and length stems as the af35 and will fit the 85-87 aero 50 and the 87 se50 and the 88 to 9? sa50 elites. dig difference is the af35 fork leg mount is higher than the metropolitan leg mounts. I had to notch the dj1 plastics under the glovebox on my 87 se50 frame. I hear you don't need to clearance the plastics if you use the met stem .
if it wasn't so d*** hard to post pics on here id post them. maybe Nate will read this and post the pics I sent him of my 87 se50'dj1 project im currently building.

[bonesv]

What also works is a honda g dash stem. It looks just like the dj-1rr stem but spaced for disc brake

[NZHonda]

We don't have all the different varieties of Honda scooters in NZ. I don't know what a Honda Metro or 'G' is! We get all of the good quality JDM un-restricted Hondas like Dio, Nifty 50 and DJ1s.

I believe my scooter is a genuine DJ1RR. It did have the fast AF05E engine in it. I bought it minus the engine as I've always intended to put in the AF18. See the pics. I've got a drum brake AF27 dio to trial run the headset and stem on the DJ1RR before I track down a proper AF28 or AF35 disk stem.

[NZHonda]

.

[NZHonda]

and some other scoots waiting patiently. The drum brake Dio is a * and is only a parts bike. My other ZX there has some wiring damage but has a 70cc cylinder (not sure what brand)

[harleyracer59]

I think yours is a dj1r (af12) not a dj1rr (af19) your scooter has single head light bulb, no rear fairing scoops, af05e engine (originally), and I don't see dj1rr on your scooterexcept for thbe forks. dj1 and dj1r have a trailing link under shock like the 85-86 aeros.
dj1=87 af05e engine dj1r= 88-89? af05e engine dj1rr 90+ af18 engine.
we didn't get any of these here. we had an se50 elite af05e= 87, sa50 elite af05e 88-93, sb50 elite non variated af05e= 88-92 sa50 elite af16 = 94-01
honda didn't seem to care if they confused the crap out of us. lol
you have a cool collection of scoots though.
you have a zx front end sitting right there. pull it offthe black zx and try it on your dj1r. then report back your findings. if the top corners of the fork legs hit your plastics, try a fork stem from a honda af55. aka metropolitan

then pull the handle bar set off the af18, put it in a box, and ship it to me!!!! lol
seriously though, I wanna buy that handle bar lights switches speedo. let me know if you wanna sell them. thanks

[bonesv]

He means the dj1 handlebars and headlight set. I didn’t see any af18 headsets on scooters in pics.

[harleyracer59]

He means the dj1 handlebars and headlight set. I didn’t see any af18 headsets on scooters in pics.

no. in the 11 post in this thread, hes has a dio sr and a zx with a disc brake sitting there. he says the dio af18 is a parts scooter and the zx has wiring issues. I already have a dj1 head set for my 87 se/dj1 swap
I was thinking, while youre pulling the head set off for me, pull the harness out of it and use it in your zx. should be swappable and that solves your wiring problem!