Re: Honda Dio, Activa and Aviator

i dont think you need to change anything
as for the emissions, the 3.5 and 4500 are the upper limits and not the 'ideal values'.. so the readings from your scooter should be below them to be emission compliant.
whether these puc equipment are properly calibrated and work as designed is altogether another story.
as long as it passes the puc, and you dont face any starting trouble, it runs fine and get a decent fe (say around 40 ish in city traffic) i dont think you should be worrying about fixing anything 'that aint broken'.

Re: Honda Dio, Activa and Aviator

Finally Activa 125CC gets a proper challenger with Fascino 125 Fi. Let us wait and see for the next few weeks. If it is liked it will be hasta la vista Activa 125. Though a bit disappointed. Was expecting Yamaha to launch NMAX or AEROX.

Re: Honda Dio, Activa and Aviator

i think a couple of years ago too, dr.pulley attended the autoexpo.. i remember getting a message from them but I couldn't attend it.
Any info on where these rollers can be purchased and their cost in India and a catalog if any ? Not in bulk but for a end user.
I am interested in buying a set of dr.pulley rollers/sliders for my old model dio, i.e. 102cc.

Honda Dio, Activa and Aviator

Are these replacement for clutch rollers used in Activa and other scooters?

Re: Honda Dio, Activa and Aviator

Hello, this is my first post on this thread.

I recently sold my Pulsar 150 and took over my brother's Honda Aviator (2009 model) as storage spaces helped me in my business related work.

But as she is 11 years old now, and with no records of the service bills, can anybody walk me through a checklist of the things I should check and clean/replace if necessary?

Today I asked a service advisor to take a ride on her, and he pointed out a few things like busted cone set, fork dust seals, brake shoes, cables, wheel bearings and maybe drive belt and probably clutch overhaul alongwith the usual servicing of the vehicle.

If the above points come true, how much of an expense am I looking at?

Also I'll be changing the engine oil and the transmission oil, along with the air filters and the spark plug.

Can anybody please help me with a good Engine oil, a good transmission oil and the cost of Aviator specific NGK spark plug please?

Re: Honda Dio, Activa and Aviator

Engine oil.. any good branded (motul, shell, castrol) 20w40 or 10w40 will do(or even a 10w30). The regular NGK plug is around 65rs, the platinum or irdium variants cost more. the regular plug part no is cr6hsa iirc for the 102cc engine.. i've been using this plug for a few years now. no issues. a few of them were sent to me by fellow forum member [MENTION=28527]sibun[/MENTION]
these days you can pick it up online on amazon. i don't think a platinum or ir plug is req.

here are links to a couple of old posts that might help you.. and do watch the full service inspection video linked in the post below:




apart from these, any other obvious damages/wear that needs to be attended to. if the tires are too old or worn, better replace them. i've seen these scoots exhibit a wobble on old (5yr old) tires (Even if they have some tread depth left). you will know how old the tires are by looking at the date code marking on the tire (e.g. 1012 : means 10th month of 2012)

Re: Honda Dio, Activa and Aviator

Hello Everyone,
I have a Hero Maestro and recently I've noticed a strange problem. I found some oil in the Air Filter box. The oil was present on the hose that takes air to the carburetor and also on the filter element. Also the filter had a smell of gasoline. I do think that that the oil had come from the PCV pipe but still not sure why. Also there is a problem of oil being reduced to 200-300 ml after riding the scooter for about 1000 kms. There is no smoke from the exhaust. The soot deposits on the exhaust is dry and the spark plug also came out pretty good. So I hardly suspect the valve guide seals and the piston rings. There was very small leak from the drain bolt so applied some RTV gasket maker and the oil was still reducing. So checked the head cover and found that there was small leak from the head cover too (although the head cover gasket has been changed 3 times). Applied the same gasket maker and let's wait for the results. Did some topup of oil along with the topup of gear oil which also was leaking due to old washers.
Also the choke cable was all rusted and snapped one night when I was trying to force it back to off position. Since I had a new choke cable with me I tried installing but was unable to do so as the floor board made it impossible to properly route the cable from the front to the back. But I did noticed that the choke was in off position. So i removed the old cable and since then the scooter is running rich. Isn't the default position supposed to be off? I will post the pictures of the carburetor soon.
Also when I run the scooter at 40kmph I notice that it feels like the clutch is slipping a bit. I've replaced the CVT belt at 25300 kms. The current odo reading stands at 34000 kms. It has been about 10000 kms when the transmission was last cleaned. So I guess it needs a cleaning. By the way any idea which rollers can be used for Maestro? The engine is same as that of Activa albeit in a different state of tune. I found these on HGPMART-

But these are not recommended for Maestro. So should I use them or use the ones for Activa?
The last part is the rear brake. It somehow lacks the bite. I know the feel and feedback from Maestro's brake isn't as good as Activa's but somehow when I got my rear brake shoes changed at 25300 kms they became even worse. No matter how tight the brakes are they won't let the tyre skid under any circumstances. This wasn't the case before the brake shoes were changed. Recently changes the brake shoes again myself and problem still persists. I guess the drum is now gone. Any idea how to check the drum and where can I find one online?

Re: Honda Dio, Activa and Aviator

Need Help,

I've Activa 2012 model. Since it's used by my Mother and Father and they don't look much into the engine oil stuff, so I went ahead and went to change the engine oil since it was due for maybe more than six months, although it's running is not that much on daily basis.
When the old engine oil was drained to my shock there was hardly any oil remaining that came out, only a few droplets, then changed with Castrol. This was done in 08.03.20.
Then the lockdown came and when the office resumed in Apr'20 I started using the Activa since I used to go office by local transport and it's still closed.
In May'20 I checked the oil indicator and it was half, there is also no leakage beneath. This was after running 1700 Kms since last oil change and my daily commute is 52 kms.
Went to local mechanic, he drained the engine oil to see how much was remaining and it was 400ml, half was gone. Changed the engine oil again with Valvoline and said to check again how much it consumes the oil. After 1200 kms now again the same thing is happening the oil level is going down. Went to the same mech and he said to run till 2000 kms and will check after that. I asked him is it safe for the vehicle to run with low oil and he said "Zyafa farak nahi padta".
So now what should I do, what could be the reason for dropping oil level. Have the components inside the engine worn out.
Thanks

Re: Honda Dio, Activa and Aviator

top up the oil and ride for now.. use a 20w40 grade oil.
since you have observed the oil level drop multiple times, it does indeed look like the scooter needs some engine repairs (assuming there is no external oil leak)
two probable causes are bad valve oil seals and worn piston rings/bore. you probably need both since the scooter ran with almost no oil..
a new block piston kit costs around 2800rs and the valve kit around 800rs iirc. Add around 2000rs for labor.
and then if the bottom end (crank case) needs some parts like new bearings, that will cost extra.
i suggest you get the entire engine rebuilt for peace of mind.. would cost around 8k incl all parts and gives you a peace of mind for next 50k km if done properly.
and don't forget to change engine oil every 3000km or 8 months whichever earlier and check oil level every week.

Re: Honda Dio, Activa and Aviator

Thanks for the reply, but isn't 10w30 grade oil used for activa?

Re: Honda Dio, Activa and Aviator

Earlier ones were recommended 20w40 in both engine and gearbox. 20w40 will offer better protection for your cylinder-bore, so go for it. You can use any good, original EP90/GL4 gearbox oil for gears.

Re: Honda Dio, Activa and Aviator

infact earlier ones were recommended 90 gear oil for gearbox and 20w40 for engine oil(an oil chart is specified in manual regarding what grade to use depending on temperatures).. my 2007 Dio had this recommendation. honda only sold 20w40 and it was suited widely for the temperatures in our country.
honda only sold 20w40 initially, and then switched to 10w30 iirc around 2011.. these scooters run just fine on either of these grades.
on a worn engine, a slightly higher grade might cause lesser oil consumption.

not sure if they now recommend the same engine oil in gearbox too.. not that it will cause big harm, but i'd say for gearbox use ep90 gl4 gear oil, doesn't cost a lot and lasts long. iirc castrol now sells their scooter engine oil along with a pack of gear oil (800ml engine oil 10w30 + 120ml gear oil)

my next oil change will be savsol 20w40 (currently running motul 10w30 scooter oil for almost a yr/3500km) in the next few days. savsol used to be the supplier for honda 20w40 back until 2010 iirc (that's when i stopped buying oem honda oil and switched to shell/castrol and most recently motul)
now its shell that seems to be their supplier for engine oils.

Re: Honda Dio, Activa and Aviator

Our 2006 Activa didn't have any recommendation - only a chart for engine oil was there in the manual. Most of us ended up using 20w40 because that was the only oil HMSI had in their SVCs (white bottle).

I don't remember what oil they used in the GB because their schedule says "replace every 2 years". Compare to Suzuki - the 1st generation Access had a 8k km change interval for GB (better for our conditions and changing 120 ml frequently won't hurt).

Yes, that's a handy offering from Castrol - the GB oil came in a toothpaste pouch with a long snout.

For 110cc, the shop manual says 20w40 in both engine and GB. Manuals of recent (2019-ish) CVT models of Honda in Indonesia/Thailand simply advise to use 10w30 in engine and GB.

Now HMSI has 4 oils in their SVC: 10w30 MA and MB, throttle and a new black bottle 5w30 MA. Interestingly, BS6 scooters can use either 10w30 MB or 5w30. I had a peep into BS6 CD110 Dream's owners manual - it can use either 10w30 MA or 5w30.

Re: Honda Dio, Activa and Aviator

All right, did the half engine work, costed around 2600/- from a local mechanic.
The mech. said to change the engine oil after 600 kms and have to maintain a speed of not more than 40 kms. Lets see how it turns out.

Re: Honda Dio, Activa and Aviator

looks like you went in for a rebore ? what other parts were replaced ?
and yes keep the speeds low and let the engine warm up for a minute on cold starts.. and change oil at 600km as advised by the mechanic. you can use any 10w30 or 20w40.. stick to reputed brands like shell/motul/castrol (easy to pick up the oil from amazon at a good price these days)

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interesting they also have a 5w30 now. maybe to squeeze out as much FE as possible and keep emissions under check.