Re: Honda Dio, Activa and Aviator

Update:
Today, I had opened the variator after riding some 800-900kms for changing rollers. Previously, I had used graphite from pencil and so its black and shiny. Surprisingly, variator was much cleaner as compared with grease setup. Even it did not require cleaning. So, no frequent maintenance required with variator.
In picture below those are 12g rollers from pleasure.


After removing rollers, it was all clean and shining.


Installed those rollers. They are 10.2-10.3g each. i did not use any grease or graphite this time.



Now, the acceleration has improved and engine feels very stressfree which is predictable. As of now it seems Honda engineers have selected the proper weights(11g) keeping both performance and FE in their minds.
I need to do some more test rides to find the top end speed and FE. I will continue with this setup for few days and then I will test 3 rollers of 10g and 3 rollers of 12g to form original 11g setup.

Re: Honda Dio, Activa and Aviator

Where did you get the new rollers(10.2-10.3g) from?
Do keep us posted with test drive results. :thumbup:

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Re: Honda Dio, Activa and Aviator

I got those rollers from local auto parts shop who is specialized in honda genuine, oem and cheap parts too.


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Re: Honda Dio, Activa and Aviator

Glad that you have removed the excess oil..most mechanics dont mind dumping in a bit more oil and will tell you that its ok.
Like i told you, even i had once filled up 900ml and rode it for around 2000km and only at the next service did i realize it was 900ml that was filled.. but i was glad i did not face an issue due to over fill.. but its always a risk
you never know what tolerances each manufacturer's have.. Manufacturer A's bike might run without issues with 100ml excess oil but B's might develop a gasket leak or develop other problems, so it better to stick to the manufacturers guidelines.. unless you want to learn from experience (which might end up costing you money and headaches if something goes wrong)

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From what i have researched, (the older dio was also exported to the UK as the SCV lead 100 and a few other countries with minor changes) - one such specification was that it had 10g roller weights in the UK
I wasn't able to locate a 10g packet from honda in india - and i have no way of telling what the original weights were in my Dio
So Ideally 10-11 should be fine, I'd use 10g if I was able to procure good quality ones.

btw.. i am yet to see a local spares shop who deals in only genuine stuff sometimes even suprious parts are packaged in 'oem' packs and sold off as oem.

Honda Activa(2013)

1. There is a pipe , @ 8 mm dia, running from the primary air filter box to the top of the cylinder head - what is this pipe for?
2. The variator cooling air inlet flexi-pipe is connected to the main frame at the bottom, forward of the variator - where does the variator fan draw the air from?

Could someone please help me with above two queries.

Re: Honda Dio, Activa and Aviator

Hey guys,
I went for a test ride at 6:00am, to check if there are any noticeable differences, I must say that Dio's engine is smoother but BEFORE the oil change, I felt the scooter was not as smooth as it would be in the evening (that is after riding a some kilometers), NOW that problem is gone.
Thanks to Shell Advance AX7 SS. :-D
I would personally recommend this Engine Oil for your Honda Dios & Honda Activas but having said that, you are free to choose amongst some other lube brands that are available in market too;
Cheers.


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Re: Honda Dio, Activa and Aviator

Any oil will feel smooth the first 200km, you need to check after that if the oil still holds good, and now Bangalore is getting hotter by the day too so test the oil during afternoons.

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Re: Honda Dio, Activa and Aviator

Alright bro, Thank you for your advice.

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Re: Honda Dio, Activa and Aviator

Honda Dio (2011)I had a hard time today opening rear body cover. I removed two 10mm bolts next to fuel-tank lid too. Had to manage with partly lifted cover to clean paper air filter; couldn't do the secondary air supply system.I changed Engine & Gear oil on our Honda-Dio: (cleaned AirFilter too along with other stuff)

Re: Honda Dio, Activa and Aviator

This 120ml EP 90 is specifically made for gear box or transmission.
Am I correct?

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Re: Honda Dio, Activa and Aviator








check the manual.. its is clearly described how to remove the rear to access the engine bay .. its called the CLIC mechanism by honda.
you need to open five 12 nos nuts (open the seat, you will see one nut in the storage box area and two more on either side approximately at the center of the seat - DO not open the two nuts near the fuel filler - and the last two nuts are on either side near the foot rests where the pillion keeps the legs)
Once you remove these 5 nuts, then close the seat & gently it lift up (lift the body from the front i.e. rider seat towards the back, not the other way around) like the bonnet of the car, and you will see a rod under near the engine bay which needs to be slotted in to a hole under the body to hold it up while you do your maintenance.

See this pic..3 nuts under seat (the one in the storage compartment hidden by the chain), two on either side and lift from front towards rear:



I think GL stands for Gear Lube , while EP stands for Extreme pressure (oil contains extreme pressure additives)

It might be ok to use GL since its a very simple 'gear box' but i'd play safe and i always use EP90 as recommended by Honda
Meanwhile Hero I think recommends to use the regular engine oil itself in the gearbox too on their scooters

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1. Its a air pipe
2. There is also a opening at the bottom of the left hand side casing (variator/belt side) - a hole big enough for two fingers to fit thru - you can take a peek underneath, below the kick start lever and near the main stand rubber. The lhs side is not 'sealed' completely..
The variator fan is the circular metal plate with fins on it (i hope this is the one you are referring to and not the engine side fan)

Re: Honda Dio, Activa and Aviator

That must be it, I convinced myself these two were missed from manual by mistake. Apparently those two bolts hold some assembly under the cover that needs to go up when cover is lifted. Will try this weekend for cleaning Secondary Air-Supply Unit.

Disagreement among manufactures only suggests that it's of little importance. I inquired at multiple shops for EP90 only to find GL90; even at the authorized Castrol dealer. I've EP140 at home as well which I procured for lubing my 150cc Bike.

What kind of headlight does Dio has? HS1/H4 35w bulb with P43t/Px43t socket, like the bigger cousins(150cc motorcycles)?

PS: Thanks for sharing spare-parts manual for Dio(SCV100 LEAD).

Re: Honda Dio, Activa and Aviator

Surprised you couldn't find the ep90 oil. Ask at a Bharat petroleum bunk for "90 gear oil" & this is their product - mak spirol ep 90


Do not use the ep140, it'd be too thick for the puny gearbox.

The old model dio has a BA20d type headlight bulb (not sure about the newer ones i.e. 110cc ones). Try the bosh max bulb (halogen) - I find it around 20% better than what came from the factory. Some pics of the actual bosh bulb (have a spare one lying under the seat and the box of a similar bulb from lumax)

Re: Honda Dio, Activa and Aviator

I was on foot collecting several tools on JC road(vicinity) B'Luru, in the middle of afternoon. I was exhausted & dehydrated esp locating a store with fork-rod. I asked for EP90 Gear oil along the way, but found GL90 all the time. Bought it from exclusive castrol dealer.

This is the one I bought & it has same API ratings as your's i.e API GL-4


Thanks for the photos & model info, it really helps.

Re: Honda Dio, Activa and Aviator

The Castrol Manual GL-4 says its a 'transmission fluid' - Maybe we should do more research (well i mean use Google not the 'lab' research) on the differences between a 'transmission FLUID' and 'Gear Oil'
Ok wait, did i just notice it said 'transmission fluid' on the top and 'gear oil' at the bottom
Maybe this will start another coffee vs toffee argument....
Let me start it off.. your 'transmission fluid' costs MORE than the Gear oil i had mentioned and mine also conforms to some US military spec