Re: HeroHonda Pleasure 07

just stick to the stock rollers and make sure you get the clutch side opened every service (usually every 3k km) and cleaned out and put back together.
it's mostly the lack of maintenance that causes more wear and tear and almost no svc will do this work during a regular service.. I've always had the clutch side casing removed and dismantled every part in there, cleaned and put back with a bit of grease on the starter bendix (don't put grease on the rollers), the rear sheave(which has the big spring). and just for a peace of mind replace the gear oil too every service or worst case once a year and use good quality gear oil from a brand such as castrol, mak spirol etc.. avoid the ones sold in loose/pouches (it hardly takes in 120ml and is a 2 minute job)
this is just my experience on my dio that's now clocked close to 70k km in 11yrs and i've replaced the rollers once just as a preventive maintenance (i think at 45k km).. of course you will notice a bit of a flat spot but that did not cause any pickup/acceleration issues, so keep an eye out and replace as required. i had also replaced the clutch shoes and springs around 55k km iirc , again as a preventive maintenance. .the old parts i throw into my parts bin as spares.

Re: HeroHonda Pleasure 07

Thank You man, but I don't think the Pulley type of roller/slider can be sourced here but thanks for the heads up.

Re: Honda Dio, Activa and Aviator

Hey, thanks. and sorry for replying after so long. I didnt do much mods after that, but just changed the clutch belt, clutch shoe and springs to OEM ones. but now my dio does 100-105. I only have aftermarket air filter and tuned Carburetor. Ive Clocked 22k kilometers now and It's pickup is still better than other scooters in market.(including access125 and excluding activa 12). I've been planning to do porting of valves. lets see how it goes.

Re: Honda Dio, Activa and Aviator

A lot of harshness while accelerating is gone [emoji7]

It’s used by my parents and you know.... they get cheated easily.
I was using it recently and found many things un hondaish and started fixing one at a time.

Engine flush and gear box flush on cards after 500 km. Will throw in a new air filter too.

Re: HeroHonda Pleasure 07

Hello there, was getting mild sound on decelerating in city limits and early morning screech when pulling (10 the year of service and 62K Odo).
Decided to disassemble the Clutch and Variator assembly.
Last time Variator assembly serviced, that was 3 years/18K km ago with rollers replaced. This time rollers have premature EOL with flat sides and Variator housing also have visible worn out grooves. So decided to change both as a set. Clutch housing been opened with little prying and greased the bearings. Clutch shoes still in good shape. Kick leaver have recently sounded clunky but pinion looks good but dry. So Kick pinion got serviced with bearing grease. Lastly oiled the bendix drive of Starter assembly. There was some confusion in Hero ASS over price of spare parts, as they were charging 10% more over MRP in the name of GST. Escalated to higher authority and refunded the overcharged amount with slight hesitation like over charging is normal for older stock. Funny experience. Total setback count 375+(53x6)+ 200 = 900
and a whole total of 5 hours

Re: Honda Dio, Activa and Aviator

Any reduction in harshness? Also, why did you not find a good local mechanic instead of putting up with Honda service centers after free service was over?

Re: Honda Dio, Activa and Aviator

Changed oil. Used regular Honda oil. Bought a can of servo gear oil.
Changed both myself. Hardly took 10 min.

Recently got to know that no mechanic ever changed gear oil in my 50K run Activa. Ran through all service invoices. No where I could find gear oil change. Hence decided to do fluid change on my own from now on.

Gear oil was thick black paste when draining. Felt bad and cheated. Now will be draining gear oil again after 500 odd kms, just to flush out all debris which had been accumulated over years.

Re: Honda Dio, Activa and Aviator

Try with Castrol instead of Suzuki oil. But please note that it is not recommended that you do the service on your own. Oil change is fine, but there are other oils to like Gear Brake oil which also need to be topped up and filled up. Further the battery, especially if it is non-maintenance free, also needs to be topped up with distilled water.

To answer your question, I have not tried other oils. I have gone only with what Honda service center puts into my activa. But yes after putting more 2500 kms in odometer the scooter does sound harsh.

I am also fed up with Honda Mineral Oil getting expired after 3 months. Honda really needs to change this and allow us to put in the oil of our choice. I never had this problem with my Yamaha vehicles. But it is only Honda which is so particular.

Re: Honda Dio, Activa and Aviator

Okay... Reviving this thread as i need some urgent help on my Activa 110.

My Activa has done over 52K kms. Running good. No problems.
The engine gets harsh exactly after 2.5K after each service. Now it needs a service, and i am planning to do it on my own. dont want to hear that BS from mechs that this is not good, etc blah blah blah.
I am tired with Honda Engine oil. Does any one has tried anything else other than Honda Mineral Oil, which performs well and doesn't get burned out so early?

Now my vehicle sounds harsh and is not able to pull properly needs a service. the last service was over 3.5K kms ago.

Can i use the newly launched Suzuki ECSTAR fully synthetic oil in Activa? any one tried FS oil in activa? what could i expect in performance change?
Any help is highly appreciated. Thanks.

Re: Honda Dio, Activa and Aviator

I have recently got my Activa 125 serviced at Honda Authorized Service Center. The detailed bill is given below. There were three significant changes
1) The service interval has been increased from 3 months to 4 months. So the total number of services in a year will be 3 in a year.
2) This is the first bill with GST.
3) The service center was not trying to sell me any maintenance plan where i have to pay about 800-1000 rs and i get some 10% discount or so on labour and parts.


The problems that I had identified were as follows
1) Engine shutdown when starting from stand still if we accelerate.
2) The panel below the side stand would come stuck.


Detailed bill

Honda Dio, Activa and Aviator

Has anyone installed a windshield on thier scooter? I'm thinking to install a good windshield since i started riding my Dio on highway.

Honda dio cdi bricked

I have a honda dio 2015 model i did some modifications of engine kill switch and hazard light wth flasher
So previous 6mths ago the cdi some how burned i replaced with a new and again almost after 6mnths day after yesterday again the cdi got burned can anyone tell me what is the fault or the problem with the scooty so that in future it won't be persist
Thanks in advance

Re: Honda Dio, Activa and Aviator

Hi guys , thank you for all the inputs regarding my Honda Activa cold start problem.
I followed the service instructions like:
1. Carburetor cleaning - complete cleaning not just bowl.
2. Got new set of primary viscous type air filters from authorized svc (cost 250 rs) and cleaned secondary air filters.
3. New spark plugs from svc.
4.Changed gear oil ( never knew it needs to be changed, it was completely black and have completely lost it's viscosity).
5.Clutch overall servicing .
6. Front suspension bush canged- it was making some squeaky noise.
7. Main problem was with secondary air filter - it's air inlet was completely blocked. Some crazy insect has made it into it's house. It had filled the inlet hole with some white color insect secreted material.
According to svc it was making my mixture lean due vaccume created because of the absence of secondary air.
8. 2 months back I had installed new amron batteries.
9. Changed rear brake shoes.

Now my old 2008 model is roaring again. Got started with just the click of a button in the morning. Easily doing 0 to 60.
Some minor vibration still present near handle and headlights are not focussed ,Light is pointing upwards towards sky I'll get it corrected soon.
Extremely happy to see it in this condition.
Thanks for this awesome thread, read it completely before going to get it serviced.Even mechanic was surprised with the little but rare knowledge I had about all the parts ( aquired by reading 1 to 150 of this awesome thread ).

Re: Honda Dio, Activa and Aviator

Bummer. Almost all Honda 2 wheelers have terrible headlight. My unicorn was no exception. Doesn’t light up the road, blinders the opposite people.

Re: Honda Dio, Activa and Aviator

Activa 125 suspension is very stiff or hard. It keeps the scooter manners on roads but the drawback is that all the potholes and all the bad roads will be transmitted to your back and to your body. This scooter, i.e. Activa 125, given its price tag deserves to have a very good mono shock absorber. But it appears that Honda two wheelers will now compromise on its margins. With Activa the TINA factor comes into play. Would definitely not recommend Activa 125 for a more plush or for a more comfortable ride. There are other scooters that you can look at for that.
Cannot comment on Aviator. When I had gone for TD they had offered me both Activa 125 as well as Aviator. I had even driven Yamaha scooters for TD. Have a look at them.


Low beam on Activa 125 is sufficient, not great but has a big wide throw. Does not light up sufficiently and is barely adequate. High beam is focused but it goes somewhere upwards in the air. It does blindens the opposite rider. Cannot comment about Aviator though. Have not driven it.