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Honda Dio 2 Buildout Help - AF18E

Posted: Wed Feb 17, 2021 4:03 pm
by hippo008
Hi there,

I'm building my first Honda motor coming from the Jog/Minarelli world. I'm planning out my build right now. I'm looking for something reliable that won't require any serious case machining for the crank webs. The current plan is a Polini Corsa Ministroker with the 43.4mm ScooterTuning crank, a Stage6 big valve intake and some combination of pipe and carb. This is where my experience fails me. Carb and pipe sizing have been a challenge for me. I asked around and here's what I heard.

The PG Short pipe is recommended. The Arrow Limited is also fairly good. Any recommendations?

Carbs are huge on Dio setups, people seem to like 26mm flatslides a lot. I'm not sure what to use. It's left me scratching my head. :newb:

As for the CVT setup I'll probably end up with the oversize ZX kit unless there's a better option out there.

Here's my scoot. Very excited for this JDM beauty. https://i.imgur.com/y9cLaAM.jpg

Re: Honda Dio 2 Buildout Help - AF18E

Posted: Thu Feb 18, 2021 4:05 pm
by Meatball
Skip the mini and go with stock stroke. Much easier to tune and the gains with mini vs stock crank is minimal unless youre going for timeslips at the track.

24mm carb is plenty big for Corsa. No matter mini or stock crank. Anything bigger and youre just wasting fuel.

Re: Honda Dio 2 Buildout Help - AF18E

Posted: Thu Feb 18, 2021 4:55 pm
by hippo008
Hi there,

I'll skip the mini stroker then. Carb sizing is a bit of an issue. Should I go down to a 21 then? I like the Dellorto PHGB carbs already.

As for the pipe I'm not sure what I want. The PG short and Arrow both seen good. Any suggestions?

Re: Honda Dio 2 Buildout Help - AF18E

Posted: Thu Feb 18, 2021 6:00 pm
by Meatball
The Arrow is double the price of PG....and worth every d*** penny. However, the PG is a good pipe for a budget build. Depends on your bankroll. The Dellorto carbs are good quality but my heart is with Polini. You cant go wrong with either brand. I think 24mm is the sweet spot for the Corsa but you can get 21mm or 26mm to work fine...any bigger or smaller then that is no bueno. My mini-stroked, race ported Corsa build didnt like a 28mm Pwk but when I switched to the 24mm it tuned easily and rips. Same carb I use on a basic “bolt-on” Corsa build. The bore just likes the 24.

Re: Honda Dio 2 Buildout Help - AF18E

Posted: Fri Feb 19, 2021 10:44 am
by ntonar
I agree, skip the mini stroke crank. If you want to do a crank the Malossi is a great and d*** near Indestructible, I will run an arrow of the PG for performance. The only downside to the arrow is that it’s a bit loud compared to the PG.

Re: Honda Dio 2 Buildout Help - AF18E

Posted: Fri May 20, 2022 8:14 pm
by hippo008
I'm resurrecting my dead thread in hopes of some sage advice!

The build has changed pretty dramatically. I have my corsa build in another Dio right now and I'm having some trouble with my current setup. I have a 51mm PG bore meant for a 44mm stroke crank of which I also have. It works out to be a 90cc~ setup.

I have a NCY pipe on there right now with a 28mm SunWorldRacing carb on a Stage6 intake. I have been unable to get this carb in tune for the life of me. I started with a large 165 jet and it died right away. I went down to the 140s and I was still getting that coughing and bogging noise, the bike just wouldn't pull. I went down to a 138 and the bike got LEAN. It was making that classic WAAA sound and Temps were spiking, it felt like there was no power. I'm at a total loss, I'm wondering if my carb is simply too large. I have a Polini PWK 26 I could try, but I'm not sure how much a difference it will make.

Any thoughts?

Re: Honda Dio 2 Buildout Help - AF18E

Posted: Sat May 21, 2022 11:01 am
by bonesv
That carb has the power jet feature which has been known to be troublesome to tune. Block the power jet with a bb or switch to a pwk style of quality meaning Polini 24 or 26

Re: Honda Dio 2 Buildout Help - AF18E

Posted: Sat May 21, 2022 9:18 pm
by hippo008
I'm going to swap the PWK 26 on there. I have a polini pwk 24 on my corsa w/ C16 and I don't want to take that apart.

The mini stroker or 125cc full stroker is going in my Dio Baja. I want a special build for a special bike!