83 Aero 50 Restoration

mbilderb · Post by **mbilderb** » Fri Jun 10, 2011 4:47 pm

Thanks to everyone for suggestions on the bystarter. If you haven't been following before, I will recap what as happened.

I purchased an 83 Aero 50 for $275 from a 'bubba'. (I use the term bubba as one who repairs repairs machines with what ever is available. Case in point is the bubba that previously owned my old 944, who tapped, then cross-threaded a machine screw on to the rotor. ) The bubba who I bought the Aero from appeared to try to pull the bystarter off with a pair of pliers and succeeded. After discovering what he did, he put it back on using a hose clamp and a piece of shop clother. Similarly, he discarded the airbox and filter, and replace it with a shop cloth and hoseclamp. Additionally, the front brake plate was broken on the ferrule the cable goes through, so bubba wired it inplace with zipties and wire.

Spree turned me onto a couple of ebay auctions, and I have since obtained a clamp on air filter, and have ordered a replacement carb. The carb is made for an 86 Aero, in that the bystarter is on the inside rather than outside. When asked about the compatiblity, the seller indicated that the bystarter will be in the way of the shock absorber; Spree has proven that to be untrue.

I have removed most of the bubbazation and receiving the air filter, have taken the Aero for a test run. The top speed is 25 mph. The compression tests out at 75 PSI.

mbilderb · Post by **mbilderb** » Fri Jun 10, 2011 4:48 pm

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mbilderb · Post by **mbilderb** » Fri Jun 10, 2011 4:58 pm

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mbilderb · Post by **mbilderb** » Fri Jun 10, 2011 5:38 pm

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mbilderb · Post by **mbilderb** » Tue Jun 21, 2011 3:37 pm

The boy and I have taken the Aero down somewhat. All plastic is off, removed the front wheel and replaced the brakes. Back Brakes look fine, but the wheel is somewhat out of round. All it will be getting is a new coat of paint unless anyone can lead me to a cheap rear wheel.

We took apart the head and saw where the head was leaking slightly, and the bottom ring was seized. Taking rings of and measuring them, they were well within spec. Will probably, just clean out and decarbon the piston and replace. The cylinger was still fairly scored, so we can probably skip the hone.

I discovered why the ignition coil was wired onto the side. The original coil was still installed without the spark plug cable, and the second coil and wire were too short to reach. Aparently Bubba cannibalized another scooter for the coil. Oh, Bubba when will I stop finding your 'modifications'? The drywall screw holding the handlebar cover together was 'un'genius.

One slight error occurred when taking the side cover off -- the kickstarter spindle came out enough to twist and tear the gasket. Now I have to take of the pulley and belt, and replace the gasket. The belt is 13 mm wide, slightly more than the service spec. Any comments on what original was? Also, is there anything in the drive train that if worn might have contributed to the slow top speed I was originally seeing? Anything that as a rule should be replaced now that it is open, and will add back to the top speed?

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richdavison34 · Post by **richdavison34** » Tue Jun 21, 2011 4:26 pm

You're going to love the new carb. PM me if you have any issues installing.

mbilderb · Post by **mbilderb** » Wed Jun 22, 2011 6:43 pm

I took the head, piston, and cylinder to the Yamaha shop (Our local Yamaha has a wizard of a mechanic) to see about boring, etc. Good news, rings and everyting are tight and within tolerances. Ring grooves, top of pistion and the head need decarboned is all.

Best of all (and this should be noted for any 83/84 aero restorers), the Yamaha 3PT-11351-00 cylinder gasket is a near perfrect match. the only modification needed is to cut the outside bolt holes. All other ports match up. I believe this gasket is for the PW50.

richdavison34 · Post by **richdavison34** » Wed Jun 22, 2011 8:01 pm

Jealous*

Let me know if you need any parts fabricated for her...ie. luggage rack.

I have an 84, so I'll be able to compare for sizing.

bradmeehan · Post by **bradmeehan** » Wed Jun 22, 2011 9:33 pm

So does that carb fit? Wonder if they fit on the 85?

mbilderb · Post by **mbilderb** » Thu Jun 23, 2011 1:01 am

bradmeehan wrote:So does that carb fit? Wonder if they fit on the 85?

I haven't installed it yet, but everything looks to line up fine. I will need to alter the cable, that is a certainty. I don't know about the 85; that years seems to be the ackward middle child of the Aero family. If you want, I will try to get you some dimensions of the carb so you can compare.

turtle13 · Post by **turtle13** » Thu Jun 23, 2011 1:36 am

Keep it up man, not much love for the 83 84 areos round here, but I myself have always loved the lines of those aeros. But then again I am partial to aeros in general...

nh_scooter · Post by **nh_scooter** » Sun Jun 26, 2011 1:59 am

Looking good, Im a big aero fan as well, i finally got my 83 NB50 running well and reliably. Have you solved your compression issue yet?

mbilderb · Post by **mbilderb** » Fri Jun 01, 2012 5:04 pm

Finally finished with the rebuild after almost a year. Still having trouble with it bogging and wanting to die when using 1/4 or so throttle, even though it idles fine. Using after market carb.

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mbilderb · Post by **mbilderb** » Fri Jun 01, 2012 5:16 pm

Sorry I didn't keep up with the thread too well.

I ended up buying air cleaner housing on Ebay and using it with the aftermarket carb. I had to cut off more of the cable than was stated to get it to work and had to move the needle to the lowest clip setting.

The Yamaha shop said the head and piston were fine and that I only needed to clean out the piston groves. I left that to my son and he did a pretty good job.

The tank was clean, but I didn't trust the oil so I drained the tank are refilled with some decent suzuki oil.

I replaced the brake shoes, tires and tubes. I did go up a size in the tires since I didn't want to pay the premium for the oem size.

You may see on the other posts, the issues I had with the electrical. For your own sake, be careful plugging into the multi port. Bubba messed me up. Luckily he only cracked it by trying to force them in offset.

I must say, I got screwed buying a replacement headlight on ebay. Although it did give me a bit of insurance in modifying the original to use an H3 bulb as a replacement.

Oh, one other point of interest: Get Insurance!! If you don't have to license your aero in your state, your homeowners insurance does not automatically cover you. I found that out the hard way.

mbilderb · Post by **mbilderb** » Thu Jul 26, 2012 4:39 pm

If you look in the 83 Aero 50 won't start post, you will see where the wristpin clip got into the cylinder and ate it up. As usual, a replacement piston and rings are not available for this model. So, just like the gasket before, I went to Yamaha. Below are the piston etc. I believe it was a base 40 bore for a razz. I had to bore the cylinder .20 over to remove the damage, so the piston is an over bore as well.

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