Re: Dio disc brake front on Elite frame

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bonesv
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Re: Dio disc brake front on Elite frame

Post by bonesv »

EDIT: Some of this post is missing from the beginning so I will try to replace it as best as I can but you can get any headset to fit on any other scooter frame as long as you are willing to take some risks, make a fearless effort, and do some real involving work with a variety of tools and machinery._____First, I went online to the yahoo japan auction site and purchased a nice condition dio af28 headset and complete front disc brake setup which included the handlebars, speedometer cowl and the wiring and headlight stem, wheels, and all the hydraulic brake system. Then I measured how much the difference was between the two scooters frame, neck and stem and calculated that if I took a 3" section out of the top of the neck on my sa50 Elite scooter and welded the top section back on like it shows in this first pic, it could fit and clear the front cover, and if I cut some of the fender underneath where the stem would have to clear the turning radius, it might work with some finessing and heating up and bending the plastic. 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. Right here I want to mention that you can get a stem from a dio with disc brakes and use that instead but it has to be a disc brake sized stem. A drum brake stem is not wide enough to make into disc brake so be sure it's for disc brake! Next, remove some of the material from the stops if you use 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, I foolishly lost the use of the key switch/locking mechanism, but you can cut around and leave the key switch mount bracket.
Last edited by bonesv on Sun Mar 08, 2015 1:59 am, edited 2 times in total.
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Honda Elite-Dio ZX

Dio ZX Headlight/Disc Brake Mod: http://hondaspree.net/phpBB3/viewtopic.php?t=30861
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Re: Dio disc brake front on Elite frame

Post by bonesv »

Assemble parts...
IMAG0856 copy.jpg
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Add the fender to estimate clearance
IMAG0864 copy.jpg
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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.
IMAG0884 copy.jpg
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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.
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Dio ZX Headlight/Disc Brake Mod: http://hondaspree.net/phpBB3/viewtopic.php?t=30861
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Re: Dio disc brake front on Elite frame

Post by bonesv »

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.
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Dio ZX Headlight/Disc Brake Mod: http://hondaspree.net/phpBB3/viewtopic.php?t=30861
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Re: Dio disc brake front on Elite frame

Post by bonesv »

Putting it together..... install the Dio legs.....
IMAG0916 copy.jpg
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finish up headset and dash......install Dio wheels/brakes and front/rear plastics
IMAG0920 copy.jpg
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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.
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Dio ZX Headlight/Disc Brake Mod: http://hondaspree.net/phpBB3/viewtopic.php?t=30861
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Re: Dio disc brake front on Elite frame

Post by bonesv »

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!
IMAG0923 copy.jpg
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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.
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Dio ZX Headlight/Disc Brake Mod: http://hondaspree.net/phpBB3/viewtopic.php?t=30861
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Re: Dio disc brake front on Elite frame

Post by bonesv »

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.
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Re: Dio disc brake front on Elite frame

Post by bonesv »

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
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Re: Dio disc brake front on Elite frame

Post by swimmingfree »

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

Post by kauaianman »

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 »

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?
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Dio ZX Headlight/Disc Brake Mod: http://hondaspree.net/phpBB3/viewtopic.php?t=30861
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Re: Dio disc brake front on Elite frame

Post by bonesv »

I have added some more pics of the finished job. Scroll back from here a bit.
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Re: Dio disc brake front on Elite frame

Post by Rip_City_Spree »

Sweet looking elite.
01 Elite SR
polini corsa
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Currently 5g rollers
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Re: Dio disc brake front on Elite frame

Post by 1man8scoots »

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 »

Nice bike love the dio headset and front disc brakes :love:
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Re: Dio disc brake front on Elite frame

Post by ped »

Very nice work bonesv. :thumbwink:
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