Aero 50 Modification Questions

DandyDan · Post by **DandyDan** » Wed Dec 31, 2008 12:49 pm

Guys,

I'm considering buying an Aero 50 for my next scooter. I'd get an '85 - '87 model (so that aftermarket parts are available for it). What I'm trying to get a sense of here is the hop up potential for this scooter. My goal is to get to 45-50 mph while largely retaining the reliability, look and sound of the stock scooter.

To my knowledge the following aftermarket parts are available:
- CDI
- Variator
- Final drive gears (from Malossi in Europe)
- Big Bore kits (63 - 65cc)
- Exhausts (non-expansion chamber)
- Carbs/Intakes/Reeds
- Various clutch springs

What I would like to do is probably the 63cc big bore kit, rejet the stock carb and then gear it taller via a new variator and maybe final drive gears (or a larger rear wheel). I don't want to switch the pipe because I don't want it too loud and I'd prefer to keep the stock carb as well.

What do you guys think of this setup? I'm mainly concerned with how fast it will get me and how reliable it will be. I've worked on a lot of scooters so I'm comfortable that I can do the work properly. Do these big bore cylinders or pistons wear out fast? Or does the added power put a lot of strain on other areas like bearings? I put a lot of miles on my scooters so I need it to be decently reliable.

Also, what would an Aero 50 perform like if you just geared it a lot taller but left the core engine stock? I don't mind sacrificing a bit of acceleration for a higher top speed because I do a lot of miles outside the city. I would be awesome if I could get to 45mph or better without a big bore kit so it would be both fully reliable and fast enough.

Thanks!
Dan
www.motorscooterguide.net

Kenny_McCormic · Post by **Kenny_McCormic** » Wed Dec 31, 2008 1:05 pm

If you go to a bore kit you have to ditch the stock oiler and run premix. You can hit 45-50 with gears and a pulley kit.

veedubh20 · Post by **veedubh20** » Wed Dec 31, 2008 9:51 pm

Just drop in a japan dio motor, there alot out there in canada...

DandyDan · Post by **DandyDan** » Wed Dec 31, 2008 10:41 pm

Kenny_McCormic wrote:If you go to a bore kit you have to ditch the stock oiler and run premix. You can hit 45-50 with gears and a pulley kit.

Sorry is this 45-50 with just the gears and pulley kit? Or the big bore as well?

DandyDan · Post by **DandyDan** » Wed Dec 31, 2008 10:42 pm

Kenny_McCormic wrote:If you go to a bore kit you have to ditch the stock oiler and run premix.

Good to know....I ditched the oil injection on my last scooter ('83 Yamaha Beluga aka Riva 80) so I'm comfortable with premixing.

Kenny_McCormic · Post by **Kenny_McCormic** » Wed Dec 31, 2008 11:17 pm

And run a lot of oil too, 25:1

Wheelman-111 · Post by **Wheelman-111** » Thu Jan 01, 2009 10:48 am

Greetings:

I have a similar scooter to yours - 87.

I installed the Polini kit. I spent an evening smoothing and widening the intake "snorkel" with trusty Roto-Zip tool. Some time I'll get around to posting Photos.

Carb and reeds are stock, tuning ongoing.

I have a Keli HSV with 9g weights. A new belt helped the top end a little more - the old one was 14.5, new = 15.5.

It did 41 or 42 during break-in - accidentally

using not much throttle. The new belt installed, in a tuck I saw estimated 44 - the needle well past the "F" on the fuel gauge. (You may need to chop the little plastic pin inside the speedometer cluster as I did...

)

The thing seems to run 43 regardless of wind, hills whatever! Gets up there remarkably quickly, then appears to climb over the torque curve and run out of breath. I've ordered some carbon sheet material to experiment with reeds. If there's a way to enlarge them I will try, perhaps with a used cage if I can find one.

The biggest limiting factor in developing more engine power on the right side of the RPM graph may be the lack of a performance exhaust. Opening up both sides (intake + exhaust) appears to be the key to the elusive 50.

Kenny_McCormic · Post by **Kenny_McCormic** » Thu Jan 01, 2009 1:40 pm

DandyDan wrote:
Kenny_McCormic wrote:If you go to a bore kit you have to ditch the stock oiler and run premix. You can hit 45-50 with gears and a pulley kit.
Sorry is this 45-50 with just the gears and pulley kit? Or the big bore as well?

Just a gear and pulley kit, stock bore.

Dac · Post by **Dac** » Thu Jan 01, 2009 1:47 pm

Kenny_McCormic wrote:
DandyDan wrote:
Kenny_McCormic wrote:If you go to a bore kit you have to ditch the stock oiler and run premix. You can hit 45-50 with gears and a pulley kit.
Sorry is this 45-50 with just the gears and pulley kit? Or the big bore as well?
Just a gear and pulley kit, stock bore.

thats with a dio motor.

Dio motor has tons of power stock.

Personally, realistically, i dont thing a stock aero bore kit could do that.

evilone · Post by **evilone** » Thu Jan 01, 2009 3:49 pm

Thanks Dac, i've been wanting to ask that question. Everyone says high speed pulley and gears to hit 45-50 with dio motor. I wondered why since another forum member lost all acceleration when installing gears in his se50. So, you think an R1 would help out even more?

maddog · Post by **maddog** » Fri Jan 02, 2009 1:22 am

they don't make gears for aero so forget about that project

reality sucks.

Kenny_McCormic · Post by **Kenny_McCormic** » Fri Jan 02, 2009 1:41 am

maddog wrote:they don't make gears for aero so forget about that project reality sucks.

Just gotta know where to look, dumbass non Michigan boys dont know jack s***!

Dac · Post by **Dac** » Fri Jan 02, 2009 2:09 am

evilone wrote:Thanks Dac, i've been wanting to ask that question. Everyone says high speed pulley and gears to hit 45-50 with dio motor. I wondered why since another forum member lost all acceleration when installing gears in his se50. So, you think an R1 would help out even more?

a dio is a completely different motor from the SE50.

My dio with a stock cylinder would spank my 92elite with a 63cc bore kit. Dio motors just have all the power you can want. I will say that for the stock cylinder 9:1 gears are better then 8.44:1 gears. But a dio will push both of them awesomely.

maddog · Post by **maddog** » Fri Jan 02, 2009 2:56 am

aero is an nb-50, been there done that 22 yrs ago & did 65mph, and i can save general motors, get rid of those college educated idiots.

DandyDan · Post by **DandyDan** » Fri Jan 02, 2009 2:27 pm

Thanks for all the help guys. I'd prefer to get an Aero 50 over a Dio (I live in Canada) because I like the styling of the Aero 50 better and because it has a glovebox. The Dio probably is the practical choice but the styling just doesn't do it for me....it looks too much like a Jog.

I really like the Aero 80 too but I'd prefer an Aero 50 for insurance reasons, because the Aero 50 has more storage and because the Aero 80 isn't that much faster on the top end. It does have gobs of power but turning that in to a high top speed seems hard. My brother has an Aero 80 with an aftermarket 24mm carb, intake and reeds and he can do about 47-50 mph (up from 41-42 mph). Perhaps a bigger rear wheel would squeeze out a couple more mph. It's too bad you can't get an aftermarket variator for the Aero 80.

There is a non-running Aero 80 in my area in mediocre condition for sale. The guy is asking $200. I think I'd rather hold out for something in a bit nicer shape. Here's what the seller said about the scooter:

the scooter has been sitting for a year under a poly tarp.The engine was running when it was put away for the winter but it did make some pretty good noises down in the crankshaft area.As to the rest of it,the body panels and gauges are all there and in fair shape.20000 kms.Needs some serious care.

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