EliteS120ccJDM wrote:On my 98 elite S (purple)..I put dio gears 16x42..and they fit like a glove...I guess the 94-01 SA50 S block is the exact same as the dio...all my upgrades all say dio..and they all work beautifully..and fit like a glove..
thats because it is a dio It has the same motor as a honda dio, and everyone refers to 94-01 elites as dios
just to let u all know, your all in for a treat for what i got going for my SE engine. still have my gears. i wanna wait till i have all my parts together then ill post the pics. to whoever put this topic as a "sticky" thanks. being that the riding season is just about over, big plans coming for the aero this winter.
da808fokai wrote:
Stock countershaft length: 1.180"
Aftermarket dio countershaft length: 1.285"
I had 0.105" taken off removed from the inner (spline side) of the dio counter gear.
Are you sure the countershaft is only 1.285 inches? Dang, I was hoping to use this mod (dio gears, 6.4 to 1) on my 84 NH125, as the bearing #'s match on the parts diagrams to my bike. I convert that to mm and I get 32.64mm. The Aero's countershaft I measure at 60.5mm, coincidentally the same size as the Chinese clone GY6 125 and 150cc 4-stroke motors, which unfortunately have a 15mm diameter at each end, while my Aero 125 is 14mm. I have no good leads on an inexpensive local machine shop, so I am trying to avoid parts I cannot modify/install myself.
Can folks here please check out the PDF I made of the Aero 125 tranny components and let me know what parts might work for taller gearing? I would greatly appreciate it. Attachments don't seem to be allowed, so here is a link to where it is posted in post #8.
I have no idea how the above dude's post got put in here.....but I am still looking for detailed and measurements on each of the Dio/Elite's shafts so that I can see what could be made to work in my NH125. Thanks!
Reading through eight pages of sometimes contradictory information did not provide reliable step-by-step information.
I'm going to look for a used rear cover with which to experiment. If I find one I will chronicle my own gear swap - see new Performance Tech thread.
Wheelman-111
Most of my money is spent on scooterparts. The rest is just wasted.
"ISO": '03 Vespa ET4 Malossi187 74MPH
Flash 9: 2001 Elite SR Contesta 72 ZX Tran, 9:1 Gears, Stock Airbox/Carb/Pipe 58.8 MPH
Punkin: 2010 Vespa/Malossi S78, 61MPH
i just wanted to say im still going strong with my gears, and there was no machining neccassary with mine, only other piece i needed was i robbed a really thin washer from a spree gear set
It has the same motor as a honda dio, and everyone refers to 94-01 elites as dios
being that the riding season is just about over, big plans coming for the aero this winter. 
