Re: Honda Dio, Activa and Aviator

Using the dipstick from the oil filler cap! Pl read the owners manual if you have one.

Re: Honda Dio, Activa and Aviator

hello everyone, this is my first post on xbhp.
I need help, I have a 2012 model activa 110(non-HET)
it has clocked 28,200+kms in 28 months and now it is burning the engine oil and I notice this thing since last two services.it burns about 600ml of engine oil within a thousand kms and their is only 150-200ml oil left at the time of drain and the engine oil looks totally burnt and black in colour, 0-40kmph acceleration is dead slow, kick feels too light and I also face starting problems in mornings or after a gap of 5-6 hours. I\\\\\\\\\\\\\\\'m really upset with this because I always change the engine oil,gear oil,air-filters,spark plug on time and sometimes I also get the carb and clutch cleaned. I belong to a small city and service of honda is pathetic that\'s why after 3rd free service a local mechanic and I use to take care of my vehicle to the best possible extent, I visited the SVC today and they suggested me for a block replacement and quoted 7000₹ and mech said get it done soon or you may have to spend about 15k so I am not going to that place again -_-
few points
*very little amount of black smoke at high rpms
*fuel-efficiency is fine
*no formation of wet black substance at the tip of exhaust.
*no valve clearances adjustment done till now even once.
*the current spark plug is now quite old (16k almost)

please suggest me what parts need to be changed and how much it is going to cost (approx)?

Re: Honda Dio, Activa and Aviator

Hi guys
I got a Honda Dio Matte Grey in December last year (2014). I had a couple of questions and please be a little specific because I am a noob when it comes to things like this, not much experience as it is my first scooter.
1. Which is the best headlight available in the market (I live in S. Delhi)? My budget is 1K. Please help . I want lights which are very bright (white) and won't burn my headlight lens
2. Does adding K&N filter help in performance or is it just a waste of money on a scooter?
3. Where can I find White LED Speedometer Console and will it drain my battery? (How much is it)
4. Where can I find Plasti-Dip and How much is it?

Re: Honda Dio, Activa and Aviator

Replies in bold.

Re: Honda Dio, Activa and Aviator

Seems like your valves are not getting properly sealed

Check the valve clearance then proceed further

from oneplus one

Re: Honda Dio, Activa and Aviator


Proceed with following checklist, your problem may be solved:

1. Change Spark Plug. (only use recommended one from Honda)
2. Change Air Filter, if not done in last 8-10k kms
3. Set Valve Clearances
4. Change Engine Oil to 20w40. Fill till last point on dipstick, dont overfill.(Approx 750-800ml if drained properly by tilting)
5. Change Gear Oil.


After all this things done, keep check on oil level on dipstick every 300kms, and report us.
If engine still consumes oil then you have to go for rebore. You can see my post few pages back, the cost will be around 3000Rs.

Re: Honda Dio, Activa and Aviator

@rajat.singh follow what Lokesh has mentioned. Engine burning oil will have blue smoke not black. And do you have any cold starting trouble ?
A rebore with a new valve kit will cost around 2500-3000rs. (rebore+new piston around 1200, valve kit around 700 + labor Rs400)
A complete new block+piston kit will cost around Rs2700 I think, labor will be the same.
The ASC usually charges a bomb for a block piston replacement, but if you do not know a good mech outside then the asc would be your best bet. And the ASC doesn't take up rebore jobs they only replace the block piston kit.

Re: Honda Dio, Activa and Aviator

Update of my Activa Engine Rebore:

Engine Oil changed at 52000 kms, just after some 250 kms from rebore. Minute metal particles were visible when drained. Colour was slightly brown.So, Engine is flushed now.

Filled with Castrol 10W30 JasoMB oil. Valve clearances checked and reset.


After running 1000 kms, the condition of new spark plug was checked, suspected to be colder than recommended.

Condition of spark plug (Bosch UR4AC) at 52,800 kms .

It looks fine. Nothing to worry about that?

Engine is running smoother, original power is restored. Does 60-70 with ease and top speed is 87 kmph.
No issues at all during morning cold start, a self start with choke at first attempt and running like new.

Re: Honda Dio, Activa and Aviator

The plug color looks like it is running on the leaner side..or maybe because of the different rated plug.
I'd say get the stock champion plug from honda or the equivalent from ngk.

Re: Honda Dio, Activa and Aviator

Guys.. need some help.
Can someone with a old model (102cc) activa or dio test the voltages at the battery under the following conditions and let me know the readings ?
1. Scooter off - Check voltage across battery terminals
2. Scooter at Idle - Check voltage across terminals
3. Rev the engine, give about 1/4th or a little more throttle - again check voltage at these higher revs.
4. Last, hook up the voltmeter across the battery terminal with scooter OFF, and then thumb the starter - What is the voltage drop you notice as you thumb the starter.

Re: Honda Dio, Activa and Aviator

I have a multi-meter at my home but since I am away from my home I cannot test. Not sure whenI can go home.

I remember 3rd reading is 14.2 volts. What is the purpose of this?

Re: Honda Dio, Activa and Aviator

Recently a relative bought an Aviator (about 3 months back/900 kms). Since he is handy with tools & complained of sudden loss in pickup after servicing, asked him to remove spark plug to check afr. The plug was ngk MR7C 9N & the carb was of keihin make. So the afr(pilot) screw is still an "air" screw like the old activas carb or is it a "fuel" screw ? As I will ask him to turn screw accordingly. .
P.S: It was running a fair bit to the leaner side.

Re: Honda Dio, Activa and Aviator

I put in a new battery yesterday (Amaron, Jan 2015 manufactured).. And for the 3rd reading.. it was around 12.7V when the battery guy checked it , so i was suspecting a RR unit failure . I can't seem to find my multimeter, and will be going to my mech tomorrow to see if we can check by swapping the RR from another activa and check the readings from another scoot too.
Electricals , a new RR unit is around 550rs I heard.

Re: Honda Dio, Activa and Aviator

Finally was able to swap the RR unit with another activa. Turns out in fact it a kaput RR unit on my Dio.
Got a new RR unit for Rs.560 (mrp 596) and the readings were back to normal. The unit from the other activa responded more 'quicker' while the unit i put in needed a wee bit more of revving.

Now I have a doubt if the RR unit I got was in fact a original unit. It was packed in the Honda packing though. While buying it, I was asked if i want a local 'star' branded one or original and I asked for original. I immediately ripped apart the pack (the shop guy was like 'saaaar') and I took out the RR unit and was surprised to see the marking "STAR" on it
So I asked him.."you told me STAR is local make then how come this one also says STAR" and he said "Quality mein farak hai"
I asked him to bring the local "STAR" and the only difference I could make out was the Back part/connector was in Blue color while the "original" was black (the existing unit on my scooter was also black but it had a longish serial number and was branded "INEL-India" and the circuit board backing gluing to heat sink finishing was neater, while this had visible glue coming out)
This shop was unfortunately not the place I usually pick up spares so we had a little 'argument' about originality and he refused to take it back so I went ahead and got it fixed on my scooter.. My mech said this was 'original' (and this shop was recommended by him and close by to his workshop)

If someone has replaced the RR unit in the past, can you post a pic and [MENTION=64883]Lokesh027[/MENTION] can you post the pic of the RR unit on your Activa.

Re: Honda Dio, Activa and Aviator

The RR unit on my Avtiva is the same factory fitted. Sorry bro, I can't help you immediately on this as I am away from my home. I am planning to go home in first week of march. I will check the unit then.

Try to visit ASC spares section and compare both the units.