Re: Honda Dio, Activa and Aviator

There are two bolt's that need to be removed to change gear oil.
the bottom one is to drain the oil and the top one is to refill the oil (fill up until u see it seep out from the top hole). this is how it is on 99% of these scooters.
here is a video showing the same on the 110cc activa:

Re: Honda Dio, Activa and Aviator

Sorry for my misquote but there was a drain,i sometimes do forget things.
Yes but the local mech did open just one nut ,is it different in 2013 DIO i asked him about this he told me "its ok i know this".

I will be going and asking the SVC guys tommorow.He has given me some leftover oil.

Next oil change will be something better for sure.I did not find ep90 in the bunk.I might have to go find at a different place all together.

I wanted ax7 10w40 and the MAK spirol you told but the bunk guys dont have gear oil.I will change it in winter.

Cheers.

Re: Honda Dio, Activa and Aviator

I have access to a 'professional' grade Ricoh scanner, so fret not.. If you are able to send me the hard copies (spiral is ok, i will 'unspiral' it), I can get it done is a couple of days.

If there was no gear oil, then it is a bad sign. The bearings in the gearbox might have gone for a toss.
Who did the oil change ? There are two nuts on the gearbox, one to drain and the other to refill.
The gearbox holds just about 120ml of oil, the quantity is less but very crucial.
I'd rather prefer using a ep 90 gear oil rather than just the regular engine oil in the gear box. some do use engine oil, but i personally prefer the ep 90 gear oil.

Re: Honda Dio, Activa and Aviator

When you change oil it feels really different as in smooth.What i was amused by was there was no gear oil while draining.


Cheers.

UPDATE DROP IN FUEL ECONOMY CHANGING THE OIL.

Re: Honda Dio, Activa and Aviator




Its not hard bind but its spiral bind.
The thing is prior to me getting the service manual I first searched for best photo copier place ,when i did the scanning in a conventional scanner from hp,epison etc.The quality of the picture weren't as good as a scanned copy from a Color Xerox machine ,I mean the one made by xerox company,when I googled the price of that model it cost as high as 7lakh or so.
Most of the places have copy machine made by Canon.

I myself have a Hp officejet 5510 even at 600dpi which takes a awful lot of time for scanning a page at that dpi,the quality is crap(for images).Those Xerox made machines still have greater detail even at 200dpi.

For those who want a copy of the activa 3g I can have it printed for a cheaper price same cost as xerox/photo copy charges.
I cannot get any other models manuals,but the aviator 102cc share the same engine with activa 102cc.

Also I did argue the point with the owner of the copy center,I mean using the same machine to scan a copy albeit its a color xerox machine but scanned in black and white mode the charges are Rs5/page but the same thing photo copied in a black and white machine costs Rs1 per page (per side its 80/paisa).Both has the capability to scan at 600dpi if i hear correctly.

Re: Honda Dio, Activa and Aviator

Appreciate your efforts!
If you could send me the hard copies (i.e. photo copies), and provided they are not hard bound (i.e. available as single sheets) , I could scan as many pages as you provide free of cost in a very short period of time and upload them.
Let me know how much a set of all those hard copies you have cost (I assume the photo copying charges are rs.1 per page or lower ). Rs.5 per page for scanning seems too much.
And if possible try to get hold of the 102cc activa or dio workshop manual.

Re: Honda Dio, Activa and Aviator

Hi guys my first post.

After some significant effort managed to Xerox/photo copy the service manual of Aviator 102cc Full and supplementary manual for 110cc, also xerox/photo copied the Activa 125.

Also managed to xerox/photo copy the service manuals (except electrical,bulb pages) of Activa 110,Activa 3G 110 HET.

I searched for best copy centers and concluded that the ones made by Xerox have the best Photo quality as good as the original may be 10% drop.

The place where I copied,I asked them to keep a soft copy of the Activa 3G full service manual in PDF.But they charge it for it ,since i didn't pay for the scanning charges which was Rs 5/page.If any one want a printed copy of it or any other PM me.
If i pay the copy center the full price of scanning(only the activa 3g) which amounts to Rs700 or so at Rs 5/page is their charges for scanning,then i can just upload it online for everyone to see.
I had to do all this in a short few hrs and return the service manuals.Don't ask me how I got the manuals.

Only the activa 3g there is a digital scanned copy at the copy center ,scanned from the original service manual book.There is no digital scanned copy of any other manual,Only the xerox paper copy i have for my use.

Re: Honda Dio, Activa and Aviator

i understand your explanation of the compression, it seems ok.
sometimes sticky piston rings will affect the compression.. the trick is to squirt a little(say around 3ml, which is around half the capacity of a 5ml syringe) oil in to the combustion chamber.
one way of doing it is via the vacuum pipe connection when the engine is running (on main stand ask someone to hold the throttle so it revs a bit higher than idle so it doesn't shut off) and use that oil can with the spout to connect to the vacuum pipe and squirt a bit of oil and rev the engine till you see the blue smoke vanish.
if you aren't able to do this, then you could open the spark plug hold and put in a few drops of engine oil and give it a few kicks (without ignition) and let it sit for a few minutes and then start it and hold the revs a little higher till you see any smoke vanish. clean the spark plug after this routine.

and yes you are right, go step by step in the order i mentioned. btw, where did you get hold of the carb repair kit and what were included in it ? sometimes a faulty float setup might also mess with cold starts, if its not the valve clearances..my money is on the carb float.

Re: Honda Dio, Activa and Aviator

Its hard to explain about the compression brother. Actually I havnt cross checked it with another old model activa bcoz I dont have access to one of those. The new HET model activa and hero Pleasure that i tried kick starting has a different feel as compared to my 2006 activa.When I kick start mine , First kick feels nice and tight, then couple of 4-5 kicks goes loose, after that 1 kick goes strong and tight as if kick starting a motorcycle, then again 4-5 goes loose and then 1 goes strong and tight. Sorry bro its hard to explain lolzz

Even if we have to do the valve clearance then also changing the spark plug to recommended one is a must , so I think we should proceed from the very basic and if it dosnt help we'll advance step step.

Next week If i get time I will personally open up the carburettor and inspect it. I wont change the tuning but only inspect if the jets are not clogged then we will be sure from the carb side. Will clean the primary filter as well if I see some dust. I will change the secondary filter as well bcoz it has gone super old and is about to fall apart.

Re: Honda Dio, Activa and Aviator

Btw, how is the compression when you use the kick ? wrong valve clearances will sometimes make the compression weak when you kick start it.
Both the stock champion and regular ngk (not the platinum or iridium) are good. have been running the ngk for around 12k km now and haven't had any issues.
Prior to that my Dio (2007, i.e. same as old model activa) had run on stock plugs (replaced every 12k km) for around 48k km. So yeah at 60k km my dio still runs fine without any major engine work. The only 'major' part that failed & was replaced was the RR unit around a year ago. Most other replacements were from regular wear & tear and preventive maintenance's.

Re: Honda Dio, Activa and Aviator

Thanks a lot for the help brother. Will get the recommended spark plug from Honda service center. Brother can you please recommend which one is the better quality product between champion and ngk. Let me check with the new spark plug if it dost help then we will try the second option for the valve clearance.Carb tuning is good I can assure you because I have been tuning bikes since school days. Throttle response is crisp and pickup is also good.I forgot to mention this in my previous post that I have already checked the Ignition coil and it shows 4 KOhms and it hasnt built up high resistance so I think thats healthy.Checked the CDI as well swapping it with another one but CDI seems to be healthy and its not the culprit.I will change the spark plug to the recommended one and report you back with the result.

Re: Honda Dio, Activa and Aviator

first get yourself the stock plug (champion prz9hc) from Honda service center.dont use these plugs that spares guys push. I am very happy with the stock plug and the ngk equivalent cr6hsa. they costbaround 80 bucks and are good for atleast 15k km.
next get the valve clearances adjusted to spec. this in most cases fixes cold start issues.

if that doesn't sort out starting issue, it could be a bad carb tune, faulty ignition coil (try swapping with another one)
for the indicator flasher cooking out, its probably a wiring issue or short somewhere.. only on inspecting the wiring would u know what's happening.

Re: Honda Dio, Activa and Aviator

Guys I need some expert advice regarding my Honda Activa old model (2006). Since one year I am facing severe starting problem. The problem only happens at the morning when the engine is cold. It takes around 20-25 kicks to start the activa. It is used by my sister and it gets impossible for her to start it at the morning so every morning it has became my leg exercise job.
This issue has been addressed to local mechanic several times, what he does is clean the carburettor and spark plug. The scoot runs fine couple of days then the starting problem arrives again. The mechanic also changed the jet kit with original honda oem jet kit and made some money out of me.

Some observations : I have inspected the spark plug myself and it comes out clean.Mileage is superb.Primary air filter changed recently so it is almost new. (paper type)
Secondary air filter also cleaned by myself.
AFR mix is good. It has been tuned by me. No carbon deposit on spark plug. AFR is on leaner side.No mis firing seen till now.Engine not smoking. No visible white smoke.Kick starting with choke also dosnt help. It seems that the scoot has its own brain and starts only after requesting it 20-25 times.Once it get started in the morning then it runs the whole day perfectly. Whole day it starts with single self start. Even without opening the throttle single push of button is enough to start the engine.At the morning even the self start also fails to start the engine. Battery is in good condition.
One more point : The Indicator Flasher gets heated and shorted out multiple times. The indicator bulb is good, only the flasher gets shorted every time I change it.
Is there any electrical issue ??
Should I personally open up the carburettor and inspect ??
I dont have the owners manual and dont remember the recommended spark plug. In last regular servicing I insisted the mechanic to change the spark plug. The market was almost close on that day unfortunately and the spares shop gave me Bosch UR4AC and said this will work. I was in doubt and dont know the recommended spark plug model. The scoot as usual worked fine for couple of days and started with one kick at the morning then stared to fail after few days.

Kindly give me some advice guys.........

Re: Honda Dio, Activa and Aviator

Thank you for the response.

I am looking at converting then into LED'S. Hence is my question here. Shall get more information after I get the scooter in hand.

Re: Honda Dio, Activa and Aviator

brake lights are always standard ba15d/1157 socket.
indicators are possibly ba9s