Honda Dio 35 is a Japanese scooter produced by Honda since 1994; the scooter was restyled in 1997. In Russia, the scooter is considered one of the most popular models, especially in the ZX version, and the scooter has gained popularity due to its reliability, huge resource and cheap repairs.

In the article you will learn about all the details of the scooter. Honda Dio 35, review, technical specifications, tuning, prices. photos and videos.

Friends, please use the content for convenience, enjoy reading!

ZX package

Honda Dio 35 was released in the innovative design of those years, “bio-design”; the design of the scooter is still relevant today. In addition to appearance, the company added three new trim levels:

• Basic;

Modification SR - in addition to the basic one, it was equipped with a combined braking system. The ZX package is considered sporty, most often the ZX is subject to tuning, already from the factory Dio 35 in this the configuration is equipped with:

• alloy wheels;
• oil shock absorbers;
• front disc brake;
• spoiler;
• after restyling in 1997 with a more productive engine.

The Honda Dio 35 scooter not only changed in 1997, in 2001 it began to be equipped anti-theft system. For the 50th anniversary of Honda, the DIO scooter was painted silver-red and dedicated a special edition to the racing team: Honda-BAR-F1.

Anniversary version

For the scooter, engineers developed the latest 2-cylinder engine for that time with an air volume of 49 cubic centimeters and a power of 7.2 horsepower(for the ZX version, for the rest 7.0)), full power was achieved at 6500 rpm. The engine is paired with a continuously variable transmission (Vmatic variator). For a Honda Dio 35, weighing 75 kilograms, these are decent technical characteristics.

In addition, rubber mounts are used for the engine and muffler, and vibrations are in the range high speed are decreasing. Also thanks to excellent spatial efficiency horizontal engine Together with the placement of the fuel tank under the floor, (large fuel tank capacity (5.0 l → 5.3 l)) and engine oil tank (1.2 l → 1.3 l), the lower surface of the central part is flattened, which makes it even more improves usability. In addition, a soft fabric mat is used on the bottom of the center section.


The suspension is equipped with sports telescopic shock absorbers at the front, front brake equipped with mechanical drive / rear type with a large diameter of 95 mm for basic modification Dio, and the Dio SR and Dio ZX modifications are equipped with excellent hydraulic discs. Combined with front and rear width tubeless tires, provides an easy and comfortable ride even in dense city traffic.
The scooter is also equipped from the factory with:

• New measuring school of instruments;
• A turn signal switch that automatically returns to the OFF position;
• New rear view mirror;
• Maintenance-free battery that does not need to be refilled with water;
• Rear spoiler with integrated brake light.

Specifications

Main Specification

Common name		Dio	Dio SR	Dio ZX
Vehicle name/model		Honda A-AF 34	Honda A-AF 35
Full length × full width × total height (m)		1.675 × 0.615 × 0.995		1.675 × 0.630 × 0.995
Axle distance (m)		1,145
Minimum ground clearance(m)		0,105
Seat height (m)		0,700
Weight / vehicle weight (kg)		73/68	75/70	76/71
Riding ability (person)		1
Fuel consumption (km/l) 30 km/h.		46,9		46,3
Minimum turning radius (m)		1,8
Engine model		AF34E ( air cooling, 2 cycles, single cylinder)
Total displacement (cm 3)		49
Inner diameter x stroke (mm)		40.0 × 39.3
Compression Ratio		7,1
Maximum power (PS/rpm)		7,0 / 6,500		7,2 / 6,500
Maximum torque (kgm/rpm)		0,79 / 6,250		0,81 / 6,250
Carburetor model		PB2E
Launch method		Type type (with impact type)
Ignition device type		Magnetic ignition type CDI
Lubrication method		Separate type of lubricant
Lubricating oil capacity(L)		1,3
Fuel tank capacity (L)		5,3
Clutch type		Dry multi-disc shoe type
Transmission type		Constantly variable speed type (Vmatic)
Transmission coefficient	1st speed	From 2.450 to 0.850		2.850 to 0.860
Caster (degrees) / Trail (mm)		25°40’/72
Tire size	Before	3.00 - 10 42 J		90 / 90-10 50 J
	Later	3.00 - 10 42 J		90 / 90-10 50 J
Brake type	Before		Hydraulic disc
	Later	Mechanical read/completion
Hanging system	Before	Telescopic type
	Later	Unit of measurement vibrational formula
Frame type		Underbone

Prices

In Russia, Honda Dio 35 is sold at secondary market, you can buy a scooter at a price of 15,000 rubles.

Video test drive

Tuning

Tuning Honda Dio 35

In this article I will tell you how, for a very reasonable 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 a thing that knows no boundaries, rules and limits on the path to perfection. But the purpose of this article will not be to discuss tuning as such, but to talk about how you can significantly improve engine parameters while spending a minimum of effort and money.

For those who don't know, two-stroke engines, by their nature, are very responsive to increasing engine displacement. Unlike four-stroke engines. In four-stroke engines, engine power largely depends on the design and configuration of the cylinder head, but in two-stroke engines, the cylinder head does not have such a significant effect on engine power. Therefore, any, even small, increase in volume two stroke engine gives a significant increase in power throughout 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 is a piston (not original, the engine has already been removed from the farm, and quite “successfully”...) with a volume of 58 cubic centimeters (42mm), and on the left is a piston, which we will install with a volume of 72 cubic centimeters (47mm).

A few words about the piston: its manufacturer is Chinese a la noname, so you shouldn’t expect high service life and workmanship from it. There is no gasket for the cylinder head and cylinder in the box and they have to be purchased separately. There is no protective coating on the piston, and this is not good, although for a two-stroke protective coating on the piston is not a critical point, but still...

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

The piston rings have clearly readable markings and their appearance inspires confidence. At the very least, it is difficult to make any complaints about the geometry and cleanliness of processing.

Now about the sad thing: it is not possible to install this piston engine without disassembling the engine and modifying the crankcase... But tuning, as we know, “requires sacrifices,” so if we want to significantly increase the power and dynamics of the scooter, then like it or not, we will have to disassemble the engine a little file the tides marked by arrows in the crank chamber.

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

The second unpleasant point, and maybe not so much, is that the standard pump of the engine lubrication system will not be able to provide the proper level of lubrication for a piston of increased volume, and therefore with a larger working area. Therefore, during operation of a scooter with a piston of increased volume in fuel tank scooter should add a little oil. In principle, this is where all the troubles associated with this piston engine end.

After modifying the crankcase, you should thoroughly wash all engine parts from any remaining metal shavings and abrasives, reassemble the engine in reverse order, and only then can you begin installation.

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

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

Now about the main thing

After installing a 72CC piston, the scooter significantly increases in dynamics and power. Believe it or not, but with skillful handling of the throttle and at the same time playing along with the body, the scooter easily stands on the rear wheel while leaving Chinese garbage dumps of various kinds far behind...

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

Features of scooter tuning

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

• you lack standard speed indicators, which do not exceed 60 kilometers per hour;
• to increase vehicle performance;
• to improve dynamics.

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

• replace the muffler with a tuning resonant pipe, previously selected for the CPG;
• rebuild the transmission based on the characteristics of the tuning pipe;
• install a carburetor that has optimal diameter diffuser;
• replace the conventional variator with a sports one (which will increase the overall efficiency of the transmission part and the acceleration response of the scooter);
• install a tuning CPG equipped with an expanded Sport class volume;
• carry out engine design using a tuning piston engine.

The above option can cost scooter owners a pretty penny, so we’ll consider next the most budget option, which will not require large expenses.

Inexpensive tuning of the muffler and transmission of Honda Dio 18

Promote maximum speed, the performance and dynamics of the scooter can be tested using simple, “folk” methods and means.

So let's begin muffler tuning Honda Dio 18. It will be necessary to use available 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 engine will noticeably perk up.

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

Next we move on to the transmission. In most cases, the increase in maximum speed and the development of dynamics are hampered by its non-optimal setting. In CVTs you can often find failed springs and half-erased 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, 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 highest indicator width of gear ratios using full belt extension to a large radius. To do this, you need to remember a simple rule: the smaller the weight of the cargo, the more gear ratio and the higher the engine speed, the heavier it is - everything, accordingly, is the opposite. It is important to select loads with 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, then you should immediately adjust the carburetor correctly, break 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, you may have to change the CPG rings. It is recommended to thoroughly polish the upper part of the piston and clean the cylinder head.

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

As you can see, to achieve your goals you can use not only expensive methods, but also very simple operations and little tricks. Just a few hours of work, and your “iron horse” will significantly invigorate and come to life. The result is an increase in maximum speed, development of dynamics and performance.

Many people, especially when buying a fifty-dollar scooter for the first time, mistakenly believe that the power and speed of their scooter will be quite enough for them. They honestly think “how much faster is 50-60 km/h and why?”

Disappointment soon sets in - you want more speed. It is after this thought that scooter owners think about tuning. Of course, 70cc piston engines, saxophone mufflers, sports CVTs, and so on look very impressive. But not everyone can pay about two hundred euros for the same tuning piston for a scooter costing 400-600 dollars - it seems somehow illogical - it’s much easier to immediately take a 70-100 cc machine. So we will try to tell you about the so-called budget tuning of scooters using the example of Honda Dio, and we will share our experience in this matter.

First of all, before you complain about the scooter, you need to make sure that the stock settings are correct, that is, the standard settings. You may be pleasantly surprised by cleaning the exhaust pipe of your scooter, air filter by adjusting the carburetor and tuning/retuning the scooter's variator.

The first thing you can (should :)) do after purchasing a scooter is adjust the carburetor; and after properly running in the scooter, remove the speed limiters. After this the scooter becomes faster. Perhaps these are all operations to increase speed for the first season.

By itself, such a filter will not give much (except for appearance and sound). After installing it, the scooter's carburetor needs to be reconfigured. It begins to become lean (there is more air, the same amount of fuel) and this can lead to burnout of the piston. Here you need to work some magic with the jet. You can drill it out. You can’t do this on your knee; you need a special tool and an experienced turner. You can drill out the thread and install a Solex jet. They say from Weber they fit without modifications. And finally, you can order it. Price approx. 1.5-2.5 euros. Of course, you can also install carbon petals on the Dio, but there is little point in this if the tuning is not so serious.

It seems like we've sorted out the intake for now, it's time to move on to the exhaust. The simplest thing is to simply clean the exhaust pipe. Here you can do things differently. Someone advises walking over the muffler blowtorch; someone cut it at the seam, cleaned it and welded it back together. After this simple operation, the scooter will become more vigorous.

So, that’s all about the exhaust for now, let’s move on to the piston. Everything is simple here if the compression is 8-10 atm. - everything is fine, if it’s lower, perhaps you need to change the rings (or the entire CPG). It is not recommended to install Chinese piston rings for three hundred rubles, such savings can lead to the replacement of the entire CPG.

It is recommended to polish the Honda cylinder head, as well as the top of the piston. No carbon deposits - more power. It would also be good to go over the windows with a polishing machine (Attention! In four-stroke engines, when cleaning the cylinder head, you should not forget that you cannot use sandpaper or a metal object to clean the valves at the point of their contact with the head body - this will lead to “depressurization”, and ultimately ultimately, to burnout of the valves).

Well, a little about Honda CVT Dio. Just install new weights - nominal ones; often heavier weights are installed at the factory. Before installing them, it would be a good idea to run a grinder along the weight paths and lubricate them with a thin layer of graphite grease.

Results - scooter Honda Dio, capable of confidently accelerating to 70-75 km/h and sometimes even more, pulling one person or two equally well. And, perhaps, the most important thing is the costs, or rather the almost absence of them (you can make the filter yourself, dig up the jet in your dad’s garage)! If you are not preparing your scooter for serious racing, but just need acceptable maximum speed and traction, then I think it’s worth doing just that.

Material used from www.moto.ironhorse.ru

Tuning is an opportunity to increase the power of a motorcycle and give it an original look. appearance, emphasizing the individuality of the owner. On our website you can choose various spare parts for tuning mopeds and scooters:

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

Sports CVTs

It's hard to imagine tuning a scooter without improving dynamics and increasing maximum speed. For a smoother change in the driven shaft speed, we suggest purchasing following models sportsvariators:

• variators HondaDioAF-18, HondaDioAF-27 / GY6 50CC (for a thin shaft of 12mm and 14mm, respectively) - suitable for tuning Honda Dio scooters, allowing to improve the maximum speed and dynamics of the vehicle;
• variators Yamaha Jog 3KJ, Yamaha Jog90/Stels – suitable for scooters of the corresponding model range; The pulley diameter has been increased by approximately 3mm, the shape of the grooves has been changed in such a way as to achieve maximum divergence, and 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 analogues, provides an increase in the speed of the motorcycle and improves its dynamics.

Sports mufflers

To perform high-quality tuning of your moped, we suggest purchasing 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”, cylinder-shaped (GY6 50CC direct-flow) and saxophone-shaped mufflers are available:

• SuzukiAddressAD50;
• GY6 125/150CC;
• Honda Dio AF-18/24/27;
• Honda Dio ZX AF-34/35;
• Yamaha Jog 3KJ.

CDI switches

These switches have improved characteristics due to the fact that the power is supplied from 12 volt windings through a voltage converter. This allows you to obtain stable spark energy at any speed. The tuning switches presented on our website allow you to increase engine power and achieve maximum speed. You can purchase 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;
• HondaDio/GY6 sports ignition coil.

Cylinder-piston group

Enlarged CPG kits for tuning Alpha-delta, Honda, Dio mopeds and other scooter models. They allow you to maximize the engine displacement, thereby increasing its power. Our online store offers the following groups of spare parts for engine tuning:

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

“site” is a guarantee of reliability and quality

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

Cooperation with us will allow you to purchase quality parts at manufacturer prices. Our managers will help you most accurately select all the necessary spare parts and arrange their delivery in the shortest possible time.