In this article I will tell you how, for a quite acceptable amount of money, you can significantly increase the dynamics and power of a Honda Tact or Dio scooter equipped with an AF24E engine. By the way, tuning is such a thing that knows no boundaries, rules and limits on the way to perfection. But the purpose of this article will not be to talk about tuning as such, but about how you can significantly improve engine parameters with a minimum of effort and money.

For those not in the know, two-stroke engines are inherently very responsive to engine displacement. Unlike four-stroke engines. In four-stroke engines, the engine power largely depends on the design and configuration of the cylinder head, and in two-stroke engines, the cylinder head does not have such a significant effect on engine power. Therefore, any, even a small increase in the volume of a two-stroke engine, gives a significant increase in power over the entire engine speed range.

So, we go to the store and buy a piston with a volume of 72 cubic centimeters (47mm). I bought myself this one, it costs 1,300 rubles, but taking into account the discount it cost me only 1,100 rubles.

For comparison: on the right there is a piston (not native, the engine has already been removed, and very "successfully" ...) with a volume of 58 cubic centimeters (42mm), and on the left is a piston, which we will put in a volume of 72 cubic centimeters (47mm).

A few words about the piston: the manufacturer has a Chinese a la noname, so you should not expect a high resource and workmanship from it. There is no gasket for the cylinder head and the cylinder in the box and you have to buy them separately. There is no protective coating on the piston, which is not good, although for a two-stroke the absence of a protective coating on the piston is not a critical moment, but still ...

The cylinder has a five-channel blowdown with a well-developed network of blowdown ports, which has a very positive effect on the increase in power, especially in the high speed zone.

The piston rings are clearly marked and inspire confidence with their entire appearance. At least, it is difficult to present any complaints about geometry and cleanliness of processing to them.

Now about the sad thing: it is not possible to install this piston engine without disassembling the engine and reworking the crankcase ... But tuning, as you know, “requires sacrifices”, so if we want to significantly increase the power and dynamics of the scooter, you may or may not want to, but the engine will have to be disassembled a little file the tides marked with arrows in the crankcase.

Tides can be cut with a file, or can be cut with a well-sharpened chisel. I cut it down with a chisel.

The second unpleasant moment, or maybe not so much, is that the regular pump of the engine lubrication system will not be able to provide the proper level of piston lubrication with an increased volume, which means with a larger working area. Therefore, during operation of a scooter with a piston of increased volume, a little oil should be added to the fuel tank of the scooter. In principle, this is where all the troubles associated with this piston end.

After modifying the crankcase, thoroughly wash all engine parts from metal shavings and abrasive residues, reassemble the engine in the reverse order, and only after that you can proceed with installation.

This piston, like any other piston for a two-stroke engine. The only difference, or most likely the difficulty, is that there are no marks on the bottom of the piston that allow the piston to be correctly positioned in the cylinder.

Therefore, when installing the piston on the crankshaft connecting rod, orient the piston in such a way that the pins of the piston ring locks look strictly at the purge port located in the diametrically opposite direction from the outlet port.

Now about the main thing

After installation, the piston volume 72СС and the scooter significantly adds in dynamics and power. Believe it or not, but with skillful handling of the "throttle" handle and with the simultaneous play of the body, the scooter easily stands on the rear wheel while leaving behind Chinese garbage dumps of various kinds ...

Tuning is an opportunity to increase the power of motor vehicles and give it an original appearance that emphasizes the individuality of the owner. On our website you can pick up various parts for tuning your moped and scooter:

• variators;
• sports mufflers;
• cylinder-piston group (enlarged);
• switches.

Sports variators

It is difficult to imagine tuning a scooter without improving dynamics and increasing top speed. For a smoother change in the rotational speed of the driven shaft, we suggest purchasing the following sports variator models:

• CVTs HondaDioAF-18, HondaDioAF-27 / GY6 50CC (for a thin shaft 12mm and 14mm, respectively) - suitable for tuning Honda dio scooters, allowing to improve the maximum speed and dynamics of technology;
• CVTs YamahaJog 3KJ, Yamaha Jog90 / Stels - suitable for scooters of the corresponding model range; the diameter of the pulley has been increased by about 3mm, the shape of the grooves has been changed in such a way as to achieve the maximum divergence, weights of different weights are supplied in the kit for more precise adjustment.
• mechanical continuously variable transmission GY6 125-150CC - suitable for the engine of the specified model or Chinese analogs, provides an increase in the speed of vehicles and an improvement in its dynamics.

Sports mufflers

To perform high-quality tuning of a moped, we suggest buying one of the sports mufflers, which will give your scooter a special and unique sound. In the online store for tuning mopeds and scooters "site", there are cylinder-shaped mufflers (GY6 50CC direct-flow) and saxophone shapes:

• SuzukiAdressAD50;
• GY6 125 / 150CC;
• Honda Dio AF-18/24/27;
• Honda Dio ZX AF-34/35;
• YamahaJog 3KJ.

CDI switches

These switches have improved characteristics due to the fact that power is supplied from 12 volt windings through a voltage converter. This allows you to get a stable spark energy at any speed. Tuning switches presented on our website allow you to increase engine power and achieve maximum rpm. You can buy the following switches from us:

• CDIHondaDioAF-27;
• CDI Honda Lead 90CC;
• CDI JH110 Delta;
• CDI JH70 Delta;
• CDI tuning GY6;
• CDI tuning Yamaha Jog 3KJ;
• Ignition coil HondaDio / GY6 sports.

Cylinder-piston group

Enlarged CPG kits for tuning Alfa-delta, Honda, Dio mopeds and other scooter models. They allow you to maximize the working volume of the engine, thereby increasing its power. The following groups of spare parts for engine tuning are presented in our online store:

• enlarged CPG sets of various diameters;
• complete cylinder heads;
• piston rings.

"Site" - a guarantee of reliability and quality

Our online store offers a wide range of parts for the repair and tuning of scooters and mopeds of various brands. Our products are characterized by high precision and consistently good quality. We offer spare parts exclusively from official manufacturers.

Cooperation with us will allow you to purchase quality parts at the manufacturer's price. Our managers will help you to most accurately select all the necessary spare parts and arrange their delivery as soon as possible.

27,28 or 18, and you have a large number of complaints against him? Of course, I really want to have a high-speed vehicle. But this scooter is not young, and its speed leaves much to be desired. The only option is to modify it, but finances do not allow making an improvement to the highest level.


I suggest looking at the limited budget tuning Honda (tuning the Honda dio 27 scooter). We will carry out all operations on the Honda Dio 27, released in 1992 and with a range of about 15 thousand km. The scooter, despite its decent age, is high-spirited and reaches speeds of up to 50-55 km per hour, which is quite common among similar mopeds. We will not buy a new cylinder-piston group, nevertheless, our tuning is budgetary, which means that it does not imply such a waste of money. We will work on what we have (see the photo of the tuning of the Honda dio scooter).
First, it is necessary to free the purge channels and the exhaust pipe from the accumulated carbon deposits. This will give the motor more power, and now it will be able to reach speeds of up to 60 km per hour. Then, cleaning from various flaws of factory casting will help the same blowing channels, which is easily done with sandpaper. As a result, our scooter squeezes out a few more kilometers per hour more. The next problem is the sub-optimal transmission setting, which does not allow achieving the desired speed. The Honda is pretty old, with tired clutch springs and half-worn weights. There is no way without costs, so it is better to stock up on new different springs and weights in advance (see the video of tuning the Honda dio). In order for the moped to start abruptly, and acceleration was more dynamic, you need to put stiffer springs. They promise high revs when starting off. We must not forget that this modification has one drawback - at low speed, the scooter can begin to wiggle from side to side and twitch. The final stage in the transformation of our scooter will be the adjustment of the variator by means of weights.


After you figured out the inlet, you can proceed to the release. First you need to clean the exhaust pipe. There are different ways to do this. You can use a blowtorch to walk over the muffler. You can cut and jam along the seam, thoroughly clean the inside, and then weld it back. After such a simple operation, the scooter will run faster. Now let's move on to the piston system. Checking the compression. If the indicator is in the range of 7-10 atmospheres, then everything is in order, if it is lower, then the rings must be changed. It is not worth saving and installing Chinese piston rings.

New weights can be installed in the variator - nominal. Before installing them, they pass with a grinder along the paths and lubricate the loads with a thin layer of graphite grease. As a result, the scooter will be able to accelerate to 75 km / h or more. The reliability of the Japanese assembly allows one person or two to be transported equally well. In terms of costs, tuning the Honda Dio AF 27 scooter refers to inexpensive work. If the owner does not plan to win serious races, but only wants to increase speed and traction, then it is worth doing exactly the above work.


Correctly selected load weight provides the widest gear ratios. If the loads are heavy, then the average gear ratio and engine speed are less, and if light, then vice versa. When all these actions are completed, the old Honda Dio 27 moped will be able to accelerate to 65 km / h. And this is quite a lot for the standard model.

Many people bought a Honda Dio scooter are sure that a speed of 50 km per hour will be enough. "Why go faster, better safe, but with less fuel." However, when some time has passed after the purchase, the owner will want more speed in order to get to their destination faster.

After such a thought, the owners think about how to tune their budget scooter and transform it into a high-speed two-wheeled "Monster". It's funny, but many call this budget miracle that way. You can, of course, buy and install a tuning Japanese-made piston on a honda dio, but its cost is more than $ 200. And to install a piston of such a cost on a device that costs about $ 500 - well, to put it mildly, it is not rational. It's easier to just buy a 100cc scooter initially and enjoy it without any tuning. Therefore, it is better to just do the tuning with your own hands and add speed to your scooter without throwing enormous costs on it.

Before you start disassembling the scooter and start improving the device, you need to figure out if your scooter is configured correctly. It is possible that if you clean the exhaust pipe, air filter and tune the carburetor, then your Honda dio will simply "fly" on the roads.

Tuning for beginners

Initially, when the device is just purchased, you need to run it in, remove the speed limit and adjust the carburetor. If you do everything correctly and avoid mistakes (especially in setting up the carburetor), then, as such, you will not need it for the first time. It will become faster and more responsive to the pressure of the gas handle.

If you like such an initial setting of speed indicators and there is no more desire to increase the speed, then in principle you can end there. With this setting, the maximum speed indicator will reach up to 60 km per hour. The difference from the basic setting is not great, but the acceleration and gaining speed itself will be much better. If you are satisfied with these indicators, then the tuning of the scooter can be completed.

More advanced tuning

If such indicators are not enough and you want your honda dio to go much faster and behave much more quickly for minimal investments, then you need to treat tuning more carefully and modernize many elements of the scooter itself.

Tuning of the piston group

The engineers who worked on the honda dio made it so that the size of the crankcase would allow replacing the standard cylinder with a 39 mm piston and installing the unit with a 47 mm one. If you crank up such an operation and choose a suitable piston with a cylinder (the same Athena is ideal), then the engine volume will increase up to 74 cc. It is worth noting that the replaced engine is most likely made of aluminum, which means that it is not necessary to be smart with different cooling systems. The engine, although larger, generates more power and increases speed, but does not require cooling.

Air filter tuning

The standard filter is not very well made and installed. The fact is that it gets dirty too often, which is why it needs to be constantly cleaned. In addition, it is installed in such a way that it is very difficult to get to it. He is also not able to pass a sufficient amount of air when installing a new piston. Therefore, it needs to be replaced.

You can install an ordinary car filter of a small size. But you need to install it in the trunk. The scooter has a sufficiently sealed luggage compartment, which is why the filter simply does not have enough air. Therefore, you need to make a small and not quite noticeable air intake. But also do not forget that a lot of dust gets into it, so it is worth making a coarse filter for the air intake.

To connect the filter and carburetor, you need to choose the right hose and just fasten it tightly. But not everything is so simple. Finding a suitable diameter is not difficult, but finding a hose that will not bend and obstruct the air is very difficult. You could choose a corrugated hose that does not bend when driving, but a strong vortex arises in it, which blocks the flow of air and thereby air ingress into the carburetor itself. To improve the operation of the engine and filter, you need to find a hose from the cooling system with a VAZ - 2110. When the suspension vibrates, it does not bend and does not create any eddies.

If everything is done correctly and a good filter is installed, then the scooter will gain speed much faster, there will be enough air for piston operation, and you will not have to clean the new filter often. In addition, the noise from the filter is almost inaudible. The speed will increase by approximately 30-40%.

Muffler tuning

If you started tuning a Honda dio and changed the piston indicators, then you definitely need to change the muffler. The standard one is simply not able to cope with the air flow that forms after upgrading or replacing the engine. In addition, the speed with such a muffler will not increase much. The scooter needs exhaust pipe replacement! The most suitable model would be from the Giannelli company, however they closed their production. But if you come across just such a model, then take it exactly. It is worth noting that having installed this exhaust pipe, you need to carefully consider the tuning of the engine and not over-lean the mixture. But if there is no such exhaust pipe for a scooter, then Tecnigas is quite suitable. This option is somewhat worse and louder, but also quite good.

Transmission tuning

Tuning a scooter will not do without reworking the transmission. The fact is that the manufacturers did not take too much care about the cooling of the gearbox overheating, which can lead to rapid wear of the transmission itself. You can make a simple cooling system that will direct the air flow to the transmission and to the gearbox itself. If you have good engineering skills, then this is quite easy to do. Speed ​​will certainly play a key role in cooling efficiency, but that doesn't mean you need to drive too fast, save your life.

Any scooter can always be rehabilitated, reconfigured and improved performance of its dynamics using not too complicated procedures. This is possible even with a limited budget, as there are good tuning options that are inexpensive.

Features of tuning a scooter

So, tuning this popular vehicle may be needed in several cases:

• you do not have enough standard speed indicators that do not exceed 60 kilometers per hour;
• to increase the performance of the vehicle;
• to improve performance indicators.

The whole process tuning the muffler of the scooter model Honda Dio 18 and its other details consists of several successive stages. Each of them provides for certain operations with a particular part. Ideally, you should do this a series of actions:

• replace the muffler with a tuning resonance pipe pre-selected for the CPG;
• rebuild the transmission based on the characteristics of the tuning pipe;
• install a carburetor that has an optimal diffuser diameter;
• replace the usual variator with a sports one (which will increase the overall efficiency of the transmission part and the throttle response of the scooter);
• install a tuning CPG equipped with an extended Sport class volume;
• carry out the design of the engine on a tuning piston.

The above option can cost scooter owners a pretty penny, so we will consider further the most budgetary option that will not require large expenses.

Inexpensive tuning of the muffler and transmission Honda Dio 18

You can try to increase the maximum speed, performance and dynamics of the scooter using simple, "folk" methods and means.

So let's start tuning muffler Honda Dio 18... It will be necessary with the help of scrap materials clean from carbon deposits and dirt exhaust pipe and purge channels. It is advisable to use sandpaper to remove blemishes and excess casting. After such a simple operation, the motor will noticeably revive.

The exhaust pipe can be cleaned in several steps: using a blowtorch, or by cutting along the seam and then welding.

Next, let's move on to the transmission. In most cases, the increase in maximum speed and the development of dynamics are hindered by its suboptimal setting. In variators, you can often find broken springs and half-worn weights. They definitely need to be replaced, so you need to purchase a set of springs and various weights in advance. First of all, we adjust the clutch by equipping it with stiffer springs.

Next step - adjusting the variator... Here you should carefully select loads of a certain weight. The goal is to achieve the greatest indicator of the width of the gear ratios with the help of the full exit of the belt to a large radius. To do this, you need to remember a simple rule: the less the weight of the load, the greater the gear ratio and the higher the engine speed, the heavier - everything, respectively, is the opposite. It is important to select loads with exactly the optimal weight, since excessively heavy ones can reduce dynamics, and light ones will reduce the possibility of developing a higher speed.

If the scooter is new, you should immediately adjust the carburetor correctly, run it in, and then remove all speed limiters. Also, you need to pay attention to the piston part: if the compression is below 8-10 atm., Then you may have to change the CPG rings. It is recommended to carefully polish the upper part of the piston, and clean the cylinder head.

And finally, the disclosure of a little secret. In factories, most often, to limit the speed, they set a limitation on the number of revolutions of the engine system. This is done using introduction of an additional wire into the electronic ignition control unit, which must be carefully removed.

As you can see, to achieve goals, you can use not only costly methods, but also very simple operations and little tricks. Just a few hours of work, and your "iron horse" will greatly invigorate and revive. As a result - an increase in maximum speed, development of dynamics and productivity.