i've faced same 'issues' like you did.. tail lamp bulb fused at 12k n then again at 20k (just one filament, the filament which lights up when the brake is applied was never fused), now its at 36k and all is well. the front right indicator fused at around 22k.

headlamp - for better lighting (around 10-20% improvement) use the Bosch halogen bulb (60rs) which comes with the same rating as oem and is much better. Also adjust the head light using the screw at the bottom to adjust it's position (by default it seems to point a lil higher)

i find the braking good enough, or maybe i've learnt to brake better over the years n the handling is simply great

along with the shell fuel(regular, nvr use the premium-i had a bad experience) use their ax5 oil (only 800ml though nvr fill up 1litre) n see the diff

s1d,
I am using the shell ax5 for past 2 services after the paid services ends. It's good. No vibs & engine is little smooth now.

Head lamp is working in good condition. When it get fused, i would change it to bosch. Recommend philips head bulbs?

oh you bet.. just smoooth like a seeelk - the honda's previous 20w40 oil was good but the ax5 is simply awesome, VFM and lasts longer - the current dose has done 3400km (and is still good for running around in the city, but i feel a bit of harshness after riding around 25km continuously) pending change this week. I was tempted to try the ax7, but decided against it cos the ax5 is doing a pretty fantastic job ! The Ax7 i've used on geared bikes and it does a great job on them..

Not used a phillips bulb, but the bosch (max bulb- halogen) is much better than stock. actually my bulb had 'fused' (low beam) after the bike went over a big pothole
and oh i had to replace the bulb holder yesterday cos the headlight wasn't working and was going on and off. I had to do with a local make (SWISS - 60rs) bulb holder after cutting and joining the socket from the old holder since this local ones socket was not mating into the bike's wiring harness. Will be picking up a oem bulb holder this weekend.

I changed my tire yesterday. A couple of weeks ago when i asked for the price of the ceat secura neo(while buying a head light holder) I was told it costs 940rs without tube.
And when i went yesterday to purchase it, there was another attendant at the shop and he quoted 850rs !! there are 2 ceat models for the activa's and dio's, one is the sportier looking secura neo and the other is the 'regular block pattern' one.
I had also asked the price at a diff shop and they had only the 'regular block pattern' one which they quoted at 840rs.

I picked up the secura neo for 850rs (the size read 90/100 53J - i guess i ve to take a look at the tire again to confirm this and its directional). and purchased a tuff up tube a couple of weeks ago from the asc for 454rs!!!! woah it used to cost 250rs 3yrs ago and 320rs around an yr n a half ago!!
And the experience with the ceat.. so far(50km) i cant make out a significant difference other than that the rear feels a bit 'softer' on speed brakers/bumps ( feels this way maybe because i was riding on a almost bald tire for the past 1000km )

Yesterday ie 12-12-12 my scoot completed 26k. I have posted my 25k experience on 27th november(actually completed on 25th).
In 17 days i have overdone 1k ? or am i crossing normal ride on everyday?

As long you maintain your vehicle properly (which i think you are) it shouldn't be a problem at all!! I have Done (a few times) 450km in two days on long trips (involving non stop 120km with a pillion) and did not face a single problem and the bike never felt strained (using the shell ax5 which even you are using).
and 1000km in 17days is normal for some people (for e.g a collegue of mine does 50-60km/day on his 50k km old activa)..so figure it out. all that these scoots need are good fuel, a clean air filter and good engine oil.. and you can keep munching miles.

can you guys tell me the cost of activa body repainting black color and any good painter in bangalore near yeshwantapura

My Dio's Kickstart lever is jammed(again!).The same thing had happened a year ago!
I'm forced to use self start(It starts with the first crank...as usual )
Using the Dio rarely but the above mentioned problem is a huge pain when I try to start it using the Kick start lever.(Using self start for morning start ups for a week now)
The rear tyre is done(center is bald but the sidewall has treads!)
The service costs are as high as ever!
The last three services have cost me 3K(in 9 months) and as usual the AFR is screwed,idling is terribly low after the service!
Still enjoying every moment on this!

yes, the kick start got jammed on mine as well and it was due to the 'kicker gear' (thinks that's what its called) or the entire kick mechanism that's on the lhs casing . the jamming can be avoided if this area is cleaned, lubed and fitted back correctly.
Actually a couple of weeks before this i replaced it because the kicker used to slip once in a while and during service i noticed that it had a broken gear tooth. and when the kick got jammed the battery was also dead unfortunately (since i was out of the country the prev 3 months and decided to replace the battery later and was only using the kick)
i left the bike at work (were the kick jammed) and bought a new battery and on using the electric start the bike started and the kick was 'freed' and it hasn't jammed till date. my mech told me to only use the electric starter and not the use the kick start a lot (unless its a emergency/battery down). Earlier i used to use the kick starter almost every time when the bike was parked and used the electric start only at signals/traffic. But now using the electric start every time because i think using(saving) the kicker for emergency sounds like a 'good' idea. and the electric start has never let me down even on cold mornings.
Coming to service costs, after the 4th free service (and some bashing of the honda asc) i never went back to them for services. I was able to locate a local mech who only does these scoots (activas, kiho's etc..) and a FULL service which includes the following:
1. wash
2. carb overhaul
3. greasing the front suspension bushes and other areas
4. removing both the wheels and cleaning the drums/scrubbing the brake shoes
5. air filters cleaning
6. checking valve clearances
7. removing the lhs case and cleaning/lubing the rollers/variator and the clutch shoes
8. battery water top up

all this used to cost 200rs 5yrs ago and now i pay 300rs. + cost of oil (gear oil and engine oil every service)

No issues till date other than regular wear n tear parts replacements and a consistent mileage of 40-44kmpl even after 36k+ kms. And it still is as zippy as it was on the day it was purchased
Some of the parts i remember replacing :
1. rear tire, yes the center wears out but the sides don't (twice, once at 16k and again at 36k recently) - front tire looks like it's saying '18 till i die' - the original mrf zapper costs over 1100rs without tube and the second time i changed to a ceat for 850rs + tuff up tube 454rs !!
2. battery replaced twice (first one from factory lasted me 3yrs due to regular use of kick, and the second one lasted 2yrs and died because i forgot to top up the water this summer and one cell had gone kaput)
3. head light bulb once, brake light twice and one indicator bulb
4. rear brake shoe at 26k km -it could have lasted another 1000km maybe but decided to change it anyway
5. spark plug 3 times - at approx every 12k km (not that they broke down but replaced them anyway)
6. Air filter 4 times - at approx every 7k km and the sponge filter that is connected to the SAI system once at 26k (again more of a preventive maintenance since these paper filters start acting up if they get wet or after a few 1000km)
7. drive belt - once at 26k (again a preventive maintenance and i keep the old one under the seat along with a plug as a spare)
8. kicker gear - once at 18k
9. cone set - recently at around 36k km - got it done at the svc right under my nose since my mech was closed for a week
10. rear wheel bearing - was changed along with the cone set job (well the bike has been thru some bad ass potholes in the past 6yrs)
11. head light bulb holder recently
12. pending odo meter repair - its been stuck for the past 1 month and should get this done soon
accessories added : 1 'dog' horn w/relay my fav since my school days(though i used it rarely but was a frequent user when i was 'younger') had it on all my bikes and removed it after a few months due to certain reasons

These scoots (as in the activa's, dio's, rodeo's etc etc) are some of the easiest to service and maintain and i have no words for the mechs who screw up these! i would suggest u hold the svc's B***S and get things sorted out and tuned perfectly. I think its more of the svc laziness that spoils the party than anything else.
the scoot has never let me down and i still love taking corners and cutting thru traffic on this and it can out accelerate most bikes upto 125cc from 0-40kmph and some badly maintained/badly driven 150's as well
i may have forgotten (getting older you see) to mention a point or two but that's pretty much my ownership summary. And i will never be selling this scoot.

Man.....You are meticulous!
Kudos!
My Dio's Stock battery conked off after I installed windtone horns/1200 Rupee "HID" bulb(It was actually a crappy Chinese one)
Re last part:
True that!
This is my first vehicle(got it when I was 16),it's been two years and 18000+ kilometers and still whoops ass

meticulous at maintaining my bikes (and this long post..by far the longest i have typed for at one go was because i had A 'peg' and some chilli chicken and was sitting at office with a light head - nothing meticulous about this )
if you add a horn without a relay you are bound to screw up the electricals/battery. and to top it off you have added a 'HID' bulb which will guarantee a quicker death of the battery! For better lighting on the older dio's use the mico halogen bulb (max bulb) that costs approx 60rs.
i used the horn with a relay and never had any issues on any of my bikes (expect the first time some 12yrs ago when i was adamant with the mech to connect it directly.. and learnt my lesson after two days of this job... youth you see )
btw this evening i punched a 6yo (and complained to his parents) in my building for shoving a stick up the exhaust of my dio (i noticed a protrusion from the exhaust and on checking it out, it was a 30cm long wooden stick!!)

average life of the stock tyres that come with the activa 110cc
mine has run 19000k and looks almost flat

i guess around 16k km (rear tyre, front should last at least 30k and more if doesn't have any structral damage or due to 'age' of the tire) for the zapper ones, that's how long they've lasted on my dio twice.. the center wears out but tread towards the sides is as still 'present'

call this number
Honda Motorcycle & Scooter India Pvt. Ltd
Kareem Towers, #19/5 & 19/6, 2nd Floor
Cunningham Road, Bangalore - 560052
Tel: 080-22282419 / 22384090 / 91
Fax: 080-22282409