Re: Honda Dio, Activa and Aviator

If your rim is not cracked or warped then you can use tubeless on it.And the toolkit is the worst I've seen.Totally impractical .It's got wrenches for sparkplug Size 12&14 open spannerA combined Philips head and flatblade screwdriver.I tried to loosen & centre the front drum brake but couldn't fit any of those into the Axel nut.Even the spanners from my pulsar toolkit did'nt fit .Atleast they should have provided tools for removing the wheels.It's as if Honda is boasting tubeless tires.

Re: Honda Dio, Activa and Aviator

Yes, the tool kit on the 110 activa seems less useful as i mentioned earlier. This was the case even before tubeless tires made their entry. IIRC it was in 2011 i think when i tried to help a friend who had a puncture at my office, it was 2am in the morning and we had no option but to call the puncture wala and pay him 150rs for the fix up. On the other hand when i had a similar issue and it was 5 am when i was leaving work, i could simply remove the wheel and take it to the repair guy and got it fixed for 50rs.
the one that came with my Dio i.e. the older model 102cc activa's and dio had all the basic tools to do most maintenance tasks.. including removing the clic cover, removing wheels, removing carb etc..

Re: Honda Dio, Activa and Aviator

The front wheel axle nut can be opened by wheel nut wrench from Maruti toolkit.
This should help others.

Re: Honda Dio, Activa and Aviator

Hey guys, can anyone tell me how to replace dot3 fluid and bleed the front disk brake of Honda Aviator. I am seeing two bleed nipples. Thanks.

Re: Honda Dio, Activa and Aviator

With the advent of winters ,my activa started giving problems ,earlier it used to Start after a long kicking and revving, and died when left throttle even after riding 50kms.
Now ,it is not starting, no matter how many kicks or revs.
So which part I need to change ..?
Spark plugs ,what else ..?
Thanks in advance.

Re: Honda Dio, Activa and Aviator

A bike requires 3 things to start:
1. fuel+air mixture
2. compression
3.spark
First try and use the choke.. pull the choke lever, wait for 10~15seconds and then use the kick or electric starter (push and hold the start button for around 4 seconds)

if that doesn't work..next, (how old is the spark plug?? use genuine plugs..and preferably get them from the service center.) remove the spark plug from the head, and let it be connected to the ignition coil and touch it against the cyl head. Now use the kick and observe if you can see any spark. if there is no spark, then remove the plug from the coil and touch the coil towards any metal part like the cyl head or frame and use kicker.. you would normally see a spark fly between the wire and frame contact. If the spark is still not present you will need to get the ignition coil checked and replaced if necessary.
Thirdly it could be bad carburetion, either a stuck float or dirty carb and maybe an air leak somewhere. Inspect the area around the carb and see if you can find some cracked hoses. Also see if the fuel is flowing from the tank to the carb by removing the pipe from the carb end.

Re: Honda Dio, Activa and Aviator

[MENTION=16602]s1d[/MENTION] first of all,Thanks for replying .
I replaced spark plug (it wasn't changed since 55000kms) .
Now ,scoot didn't start.
Mechanic told me that it had lost pressure .
He offered to change head valve and all (700₹ kharcha) or a 50₹ jugaad in which he tightened/loosened valve .
I opted for 50₹ jugaad. He just opened head assembly and loosened/tightened(I don't remember) two bolts of head .voila, activa came back to life .
He said this might hold for a 5-6 month's or gave up out of no where .
My question .
Will this be good ..? Or it may lead to further more damage ..?
Now scoot comes to life in just 1 sec self ,WITHOUT even revving,which used to happen on this activa some 4 years ago.
Ps- got myself NGK plug for 60₹

Re: Honda Dio, Activa and Aviator

This was same condition of my activa 1 year ago. That jugaad (setting up clearances) was holding good till now but Tappet is near to its limit of adjustment.

But I could not understand why this thing happens, what is the technical explanation behind this?

Anyways I will get the head work done when I go home. I will check the oil level and decide whether to go for a bore or not.

Re: Honda Dio, Activa and Aviator

The technical explanation is simple: Wear between the valve and the seat i.e. the area of the head where the valve sits while it is in closed position.(factors such as age/mileage, engine oil, how the scoot was ridden etc.. play a role in the wear and tear) & the mech probably opened up the valve cover (not the entire head) and adjusted the clearances.
There is only so much of an adjustment that can be made, before you need a replacement valve kit and have it seated properly.. for which the head needs to be removed.
I have personally noticed what a difference correct valve clearances can make on these scoots, especially with starting troubles due to compression loss. I mentioned compression in my prev post, but guess i forgot to write further about it and stopped at the plug was too tired after a almost 600km ride over the weekend!

Re: Honda Dio, Activa and Aviator

Yes ,after yesterday's adjustment of valve clearance, oh my god, today in 5`c ,activa came to life with just 2 sec self and no revving.
And it used to take 5-6 kicks +high revving just to start it .and then constant revving till 5 min so that It doesn't stops .
But now ,just a push and its ready to roll.
Feels like New one.

Re: Honda Dio, Activa and Aviator

Sister was complaining about engine-stalling during idling. Esp near speed-breakers and potholes.

So,
- Went for a spirited ride for 6-7 kms @50-60 km/hr
- For the first time I removed the seat. So much easy to remove & convenient to work on. Now I don't understand the need of that support rod.




- Dusted the all visible parts, all the dust left me with coughing for a while
- Checked SAI/PAIR foam-filter. It was clean, just wiped the muck settled on the top cover insides.
- Checked viscous air-filter. Not much dust settled on the filter. Removed the rubber-lining of the cover. Wiped the air-filter cover interiors and replaced the cover then screws.
- Removed the NGK-CR6HGP plug, gosh it was a tedious task. Noticed that plug-cap was from ANU. Firing & electrode/ground tips were clean, but carbon deposits on circular electrode/ground coupled with dry carbon on the exhaust tip suggested a rich-AFR.
- Fiddled with Idle-Screw & Pilot/AFR screw by only rotating them 1/8 turns either way from original position. Idle was stable now.
- wiped carbon deposits on exhaust-pipe-tip/outlet with clean cloth

Will check the idling stability and carbon deposits after few days.

Re: Honda Activa engine oil level goes down

please reply


i am not a technical person . I have a 2004 model Honda Activa. I had done 38000+ kms till now. iam doing regular maintenance services every after 3 / 4 months.


the problem is....The engine oil level goes down within a 1/2 week of topping up. It seems the engine is burning up engine oil.


my recent visit to Honda services , they said my activa needs engine work where whole engine would be opened & that would cost 12 to 15k! upon asking
they said, the "valves" of engine has eroded




what is the real problem ...some one explain...why this happen ???

Re: Honda Dio, Activa and Aviator

Most probably engine block, piston rings or piston has worn out so the Mobil is getting inside firing chamber. Is the vehicle giving any white smoke like 2t scooter ? If yes then yup it do needs some work.

Sent from my Moto E using Xbhp Connect .

Re: Honda Dio, Activa and Aviator

Please could you specify how & which components of head assembly were removed to set tappets and of course set timing at compression Tdc..Will be of great help

Re: Honda Dio, Activa and Aviator

Yes, it could either be the valves or you might need a new block piston kit along with new valve kit.
A original valve kit costs around 700rs and a new bore+piston kit around rs.2800.. even if you replace all the seals and bearings, the cost of spares should not exceed 6000rs unless they are going to change the crank/con rod. Labor charge of rs.1500 is a good amount. So in all, if you get it done from a 'trusted' mechanic it should cost you 8k max.
authorized svc will rip you off for engine rebuilds, because most people do not know what go in to a rebuild and are under a false assumption that 'everything is new'

Why don't you first ask the honda service as to what are all the parts that they will be replacing and get the price break down of at least the parts .

Only the valve cover on the head needs to be removed. It is held down by two nuts and a thick rubber gasket
experienced guys will get to the tdc (on compression stroke) by just rotating the engine clockwise thru the fan cover side and 'feeling' the tappets and watching the valves open and close (not necessarily using the visual markings on the engine, but you can align the holes markings on the timing chain sprocket)
A few pics would be worth a 1000 words.. but unfortunately i do not have the pics to show. Maybe i'll click some in a few months when i go in for a service.

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Get the valve clearances set correctly and also just increase only the idling a wee bit (do not touch the afr screw)