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Old 26th June 2016, 12:04   #1
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Default Honda Activa DIY: Headlight upgrade and LEDs for indicators + tail lamps

I have just got home the Honda Activa 125 in White colour - Here's the Review of it

In this thread I am putting the procedure to change the lighting of the scooter to better it out from the OEM setup. The OEM setup and specifications for the lighting setup is:

Honda Activa DIY: Headlight upgrade and LEDs for indicators + tail lamps-lighting-specifications.jpg

I have done the following minor modifications to the setup.

1) Headlight - Swapped the OEM bulb to Osram;


2) Indicators - Swapped the OEM bulb to LED's;



3) Tail/Stop lamp - Swapped the OEM bulb to LED's.

I will be giving the details for the individual changing of bulb in the respective posts.

Last edited by a4anurag : 16th July 2016 at 22:03.
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Old 27th June 2016, 01:23   #2
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Default Swapping the Headlights

1) Headlight - Swapped the OE Halonix to either Osram Silverstar HS1 35/35W or Philips Rally Moto Halogen HS1 40/40W

After I had got the scooter, I went out at the night to check the light performance and was disappointed due 4 reasons:
  1. Low power of OE bulbs
  2. Reflector design fault IMO - It was replaced under warranty solving the issue.
  3. Adjustment of the light beam with respect to Road
  4. AC Setup

The OE bulb was Okay but the lights were spread all over the road (read scatter) so visibility was poor especially when in Low Beam. On the other hand the high beam was sharp and pointing upwards towards the trees.

With the scatter at low beam, nearby object at speeds of 30 kmph were hardly visible making me frown and strain my eyes to ride. So I thought of two options:

Option A: Swap to a better brand bulb like Osram or Philips with OE rating.

Option B: Upgrade the rating from 35/35W to 60/55W. It is doable but I am not sure of the electricals can take the load or not and moreover the 60/55W is a H4 P43t base bulb so it needs slight modification to fit in the OE holder of HS1 which is PX43t base. Slight difference between the two but I was not confident to go about this modification on a AC Setup.

So in the end it was Option A that I went for and got myself a pair of Osram Silverstar HS1 and now also a pair of Philips Rally Moto Halogen (40/40W).

A pair of Osram Silverstar HS1 (35/35W)
Honda Activa DIY: Headlight upgrade and LEDs for indicators + tail lamps-img_20160301_050139.jpg

I'll be putting down the process to change the headlight bulb on the Activa 125. To change the bulb there are 3 steps, mainly:
  • 1: Headlight cowl removal
  • 2: Changing the bulb
  • 3: Re-installation of the Headlight cowl
__________________________________________________ _______

1:Headlight Cowl Removal

Not difficult part but i'll say the delicate part of the D.I.Y. Reason being the cowl is too thin and delicate plus any little flexing will be prone to rattling as panel gaps will be created. One needs to be extremely careful when fiddling with the headlight cowl.

Apparatus Required:
  • 12 x 14 spanner
  • Star screwdriver

Tool Kit:
Honda Activa DIY: Headlight upgrade and LEDs for indicators + tail lamps-38.-toolkit-contents.jpg

Procedure:

Step - 1: Open the 4 screws from the instrumentation cluster to free the headlight plastic cowl.

Step - 2: Dismantle the rear view mirrors on both sides as it will be an hindrance later on when removing the cowl from the holder. You'll need the 12 x 14 spanner that is present in the tool kit.

Step - 3 (Optional): Open the Central cowl so that opening the screw Number 5 which is located below the headlight levelling screw can be easily accessed. This is an optional step. I tried using extension bar, testers etc etc but none of them could reach the screw in there because of the low gap between the levelling screw and central cowl.

Step - 4: Once Step - 3 is performed, open the screw number 5 that holds the headlight cowl. This screw is located at the base of the levelling screw.

Step -5: Once all screws have been removed, go in front of the scooter and hold the wheel with your legs and slowly pull the cowl towards you. Don't go too hard here as it is easy to damage the paint of the cowl plus there are high chances of breakage.

Step - 6: Once the cowl is free from the handlebar, disconnect the two connectors i.e., Headlight bulb & Pilot lamp.

Step - 7: Part of the bulb is over. Now time to change the bulb.

With is solved, I'll add up the pictures so that it is easy to understand the main steps.

Screws holding the headlight cowl
Honda Activa DIY: Headlight upgrade and LEDs for indicators + tail lamps-2.-screws-open-headlight-cowl.jpg

Dismantling of the rear view mirror
Honda Activa DIY: Headlight upgrade and LEDs for indicators + tail lamps-rvm-dismantling.jpg

Central cowl that needs to be opened for accessing Screw Number 5.
Honda Activa DIY: Headlight upgrade and LEDs for indicators + tail lamps-1.-front-apron-central-cowl-access-battery-relays.jpg

Two screws on each side so 4 in total need to be removed to open Central cowl
Honda Activa DIY: Headlight upgrade and LEDs for indicators + tail lamps-screws-open-central-cowl.jpg

Disconnect two connectors (Headlight and Pilot Lamps)
Honda Activa DIY: Headlight upgrade and LEDs for indicators + tail lamps-3.-disconnect-headlight-pilot-lamp-coupler.jpg


2: Changing the bulb

Step - 1: After the headlight cowl is free, holding the cowl firmly, open the rubber dust cap (Round shaped) that is located on the reflector unit.

Step - 2: After the dust cap is removed, press the on the steel clip that holds the bulb tightly. Just press down on the clip and push it forward to free the bulb from its retainer clip.

Step - 3: Remove the OE bulb and replace it with Osram one.

Step - 4: Follow steps 1 and 2 in reverse order.

Dust cap that needs to opened
Honda Activa DIY: Headlight upgrade and LEDs for indicators + tail lamps-4.-pull-off-rubber-boot.jpg

Press that clip and push it forward to release the holder clip from the bulb
Honda Activa DIY: Headlight upgrade and LEDs for indicators + tail lamps-5.-press-tab-lift-free-bulb.jpg

Halonix bulb removed
Honda Activa DIY: Headlight upgrade and LEDs for indicators + tail lamps-6.-oem-bulb-removed.jpg

Halonix vs Osram Silverstar
Honda Activa DIY: Headlight upgrade and LEDs for indicators + tail lamps-7.-halonix-vs-silverstar.jpg

Osram's installed
Honda Activa DIY: Headlight upgrade and LEDs for indicators + tail lamps-8.-new-bulb-replaced.jpg


3: Re-installation of the Headlight cowl

Step - 1: Follow the steps mention in Headlight cowl removal step in reverse order to refit the cowl.

__________________________________________________ ________

Here are the pictures of the Osram Silverstar. In the Low beam picture, look at that shadow that I was referring to. It is highly irritating to have that when riding around.

Phoenix - Low Beam
Honda Activa DIY: Headlight upgrade and LEDs for indicators + tail lamps-phoenix-low-beam.jpg

Osram - Low Beam
Honda Activa DIY: Headlight upgrade and LEDs for indicators + tail lamps-osram-low-beam.jpg

Phoenix - High Beam
Honda Activa DIY: Headlight upgrade and LEDs for indicators + tail lamps-phoenix-high-beam.jpg

Osram - High Beam
Honda Activa DIY: Headlight upgrade and LEDs for indicators + tail lamps-osram-high-beam.jpg

__________________________________________________ _________

Conclusions:
  • A major flaw in my eyes, a shadow line when the lights are on Low Beam. It is very irritating since that is the line of vision and Honda is clueless and says it is normal. The issue has magnified with the bulb swap from Phoenix (OEM) to Osram Silverstar. I have sent a mail to Honda, lets see what they have to say about it - UPDATE: Issue solved as mentioned below on 06.07.16 by ASC under warranty.;

  • I find the Osram better in light output with a flat beam when in Low Beam whereas the High Beam one was sharp and feels more like an arrow. Even though the power rating for both the bulbs are 35/35W, the Osram feels brighter than Phoenix.;


  • Getting a headlight bulb at 140 bucks is cheap IMO.

In the conclusions part, the first point is now addressed as the complaint I raised at the Honda through their website got me the replacement of the reflector unit thus solving the issue. Here is the picture of the low beam post reflector unit change:

New Reflector Unit:
Honda Activa DIY: Headlight upgrade and LEDs for indicators + tail lamps-new-reflector-unit.jpg

New Low beam pattern
Honda Activa DIY: Headlight upgrade and LEDs for indicators + tail lamps-new-low-beam-after-change.jpg

Before vs After
Honda Activa DIY: Headlight upgrade and LEDs for indicators + tail lamps-before-vs-after.jpg

After the reflector unit change, the headlight is much much better and spread is a lot even throughout the road and the stock Phoenix bulbs itself feels decent enough. Can't wait to swap the OEM for either Philips Rally Moto or Osram Silverstar. Time only will tell which one excels.

Thanks to BHPian Sulivan, I have got a pair of Philips Rally Moto Halogen (40/40W) bulbs with me now. Thanks for couriering it and taking all the pain!

With the Headlight issue solved now, I will post a comparison between the headlight bulbs that I have.

OEM: Phoenix (35/35W);
Upgrade 1: Osram Silverstar (35/35W);
Upgrade 2: Philips Moto Rally Halogen (40/40W).

Philips Rally Moto Halogen (40/40W HS1)
Honda Activa DIY: Headlight upgrade and LEDs for indicators + tail lamps-img_20160709_224432tile.jpg

Philips and Osram
Honda Activa DIY: Headlight upgrade and LEDs for indicators + tail lamps-img_20160709_224508.jpg

Last edited by a4anurag : 16th July 2016 at 22:09.
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Old 27th June 2016, 22:54   #3
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Default Swapping the Indicators

2) Indicators - Swapped the OEM bulb to LED's

I have a love for LED indicators and I have tried my hands on replacing the indicators on both my car (Swift ZDi) and my earlier bike (Karizma R). I was successful in changing the indicators only on the Karizma.

The Swift has the indicator relay embedded in the BCM unit (Body Control Module) so it is impossible unless one add a resistor in the circuit. This means I had to splice wires and I was not ready to do it hence it was abandoned.

In the Karizma's case the OEM relay didn't let the LED bulb flash as the circuit was thinking that one of the two bulbs have fused so the bulbs glew once and freezes - No blinking action. So I got myself a Solid State Relay from EBay for 150 bucks and swapped it with the OEM relay. Voila!! LED indicators worked on my Karizma.

Bizarre Moment: Just for trial purpose I replaced the rear bulb with the LED and tried switching on the indicator and it was working as intended. I was surprised since the circuit should have thought that one bulb would have fused but it didn't happen and it worked. To be doubly sure, I replaced the front bulb and checked and it worked. I was like

Reason: I bought a solid state relay in anticipation and with past experiences to be using it in the Activa but there was no need as the OEM relay was Okay and the LED's were working as it should.

Here's how to replace the indicators:

1) Front Indicator bulbs

In the Activa 125, the indicator bulbs are placed on the front apron panels just below the central cowl. To gain access, one needs to remove the central cowl.

Tools Required:
  • 12 x 14 spanner
  • Star screwdriver

Procedure:

Step - 1: Place the scooter on main stand and remove the key from the keyhole.

Step - 2: Using the star screw driver remove the 2 screws on each side to free the top portion of the central cowl.

Step - 3: With one hand hold the top portion and with the other hold the base of the central panel (It the Y-Shape Chrome) and with little force pull the panel outwards. It is slightly hard but one needs to use slight force. The cowl is held by 5 grommets.

Step - 4: Once the central cowl is free, just open the bulb holder by rotating it clockwise. Replace the bulb and reinstall the holder back into the housing by rotating it anti-clockwise.

Step - 5: Follow steps above in reverse to reinstall the central cowl.

Good to go now.

Disclaimer: When one is performing these steps ensure extra force isn't used as central cowl top portion is held by 4 screws and they have these U-Nuts on the cowl itself and are self-locking types. I accidentally dropped one of it inside the apron and to my bad luck, I had to strip the whole front end of the scooter to get that U-Clip.

U-Clip
Name:  U Nut Large.png
Views: 21572
Size:  217.3 KB

I'll put that in steps too in case one is looking to opening up the front end plus one wants to change the relay, the front-side aprons needs to be removed to gain access to the relay box. Here's how I opened the apron:

Step - 1: With the central cowl removed, remove the 3 screws holding the aprons in place located near the riders legs;

Step - 2: Remove the plastic plate-like located behind the front wheel that is held by 2 screws;

Step - 3: Remove the screw at the base of the foot board that hold the foot board + apron together.

Step - 4: Disconnect the indicator coupler and then remove the 4 screws surrounding the horn. This will free the apron. Repeat the above steps for the other side.

Step - 5: Follow these steps in reverse order to re-install the aprons.

2) Rear Indicator bulbs

Procedure:

Simplest and easiest of the lot.

Step -1: One just needs to slide the palm from beneath the lights and body to get access to the bulbs.

Step -2: Once the bulbs are located, rotate the holder clockwise direction to free it from the housing. Replace the bulb to LED.

Step -3: Place the holder in the housing and rotate it anti-clockwise to secure the holder. Good to go.

I'll let the picture do more talking....

Central cowl and side aprons
Honda Activa DIY: Headlight upgrade and LEDs for indicators + tail lamps-1.-front-apron-central-cowl-access-battery-relays.jpg

Two screws on each side to open the central cowl
Honda Activa DIY: Headlight upgrade and LEDs for indicators + tail lamps-screws-open-central-cowl.jpg

Central cowl removed. The couplers are of front flashers
Honda Activa DIY: Headlight upgrade and LEDs for indicators + tail lamps-2.-central-cowl-opened.jpg

Open these 3 screws located on side that hold apron
Honda Activa DIY: Headlight upgrade and LEDs for indicators + tail lamps-3.-screws-open-front-apron.jpg

The plastic mud guard that holds the apron along with foot board screw
Honda Activa DIY: Headlight upgrade and LEDs for indicators + tail lamps-4.-screws-open-front-apron-both-sides.jpg

Screws at the front holding the aprons
Honda Activa DIY: Headlight upgrade and LEDs for indicators + tail lamps-img_20160613_145248.jpg

Front apron and central cowl removed exposing the whole front end
Honda Activa DIY: Headlight upgrade and LEDs for indicators + tail lamps-5.-both-sides-aprons-opened.jpg

Relay box that houses the starter relay and Indicator relay
Honda Activa DIY: Headlight upgrade and LEDs for indicators + tail lamps-6.-starter-flasher-relay.jpg

OEM Indicator
Honda Activa DIY: Headlight upgrade and LEDs for indicators + tail lamps-7.-oem-indicator-holder.jpg

LED Indicator
Honda Activa DIY: Headlight upgrade and LEDs for indicators + tail lamps-8.-led-indicator-holder.jpg

OEM vs LED - Indicator
Honda Activa DIY: Headlight upgrade and LEDs for indicators + tail lamps-9.-oem-vs-led.jpg

The type of indicator I used
Name:  Indicator LED.jpg
Views: 20877
Size:  56.2 KB

Last but not the least, here are three videos showing how the LED's are lighting up the indicators. Please pardon me for the clarity as it was shot using my OnePlus One mobile.






Last edited by a4anurag : 27th June 2016 at 23:32.
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Old 27th June 2016, 23:35   #4
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Default Swapping the Tail/Stop Lamp

With the Headlight bulb and Indicators swapped successfully, I'll want to stress on a last point that is important post this DIY for proper riding later on. It is re-adjustment of the Rear View Mirrors (Henceforth shall be referred as 'RVM'). It is not rocket science but a pain if not adjusted properly keeping both the RVM's in line so that the vision is correct and equal at the back when viewed through it.

The RVM is mounted by a stem bolted by two different nuts (12mm and 14mm). I'll outline the process to adjust them correctly:

Honda Activa DIY: Headlight upgrade and LEDs for indicators + tail lamps-img_20160625_155605.jpg
  1. Take the bike/scooter outside and park it on centre stand.

  2. While sitting on the seat, fit the RVM by turning it clockwise so the 14mm bolt is seated fully. Then take a 14mm spanner and tighten it fully. Repeat the same for the other side too.

  3. Once done take the 12mm spanner and align any one RVM correctly till the field of view behind is ideal for usage. Once done, tighten it fully.

  4. Use a scale or imagine a straight line between the two mirrors. They must be straight so that the view is correct and symmetric. Once that is found tighten that bolt too securing both the RVM's correctly.

  5. Last but not the least, slip back the rubber boots over the nuts and go for a ride to check if the adjustment is good or no. Any minor adjustments hereon would be easier.

__________________________________________________ ___________

3) Tail/Stop lamp - Swapped the OEM bulb to LED's

Procedure:

Simplest and easiest of the lot as it is the same way as we did during the indicator swap since the unit is single .

Step -1: One just needs to slide the palm from beneath the lights and body to get access to the bulbs.

Step -2: Once the bulbs are located, rotate the holder clockwise direction to free it from the housing. Replace the bulb to LED.

Step -3: Place the holder in the housing and rotate it anti-clockwise to secure the holder. Good to go.

Here are some images:

OEM Bulb - P21/5W (1157 Type)
Honda Activa DIY: Headlight upgrade and LEDs for indicators + tail lamps-1.-oem-bulb.jpg

OEM Bulb Base
Honda Activa DIY: Headlight upgrade and LEDs for indicators + tail lamps-2.-oem-bulb-base.jpg

Bulb Holder
Honda Activa DIY: Headlight upgrade and LEDs for indicators + tail lamps-img_20160627_172530.jpg

OEM Bulb - Pilot Lamp ON
Honda Activa DIY: Headlight upgrade and LEDs for indicators + tail lamps-oem-pilot-lamp.jpg

LED - Pilot Lamp ON
Honda Activa DIY: Headlight upgrade and LEDs for indicators + tail lamps-led-pilot-lamp.jpg

LED - Brake Light ON
Honda Activa DIY: Headlight upgrade and LEDs for indicators + tail lamps-led-brake-light.jpg

Philips Xtreme Vision LED
Honda Activa DIY: Headlight upgrade and LEDs for indicators + tail lamps-p215w-xtreme-vision-led.jpg

LED Bulb
Honda Activa DIY: Headlight upgrade and LEDs for indicators + tail lamps-led.jpg

Last edited by a4anurag : 16th July 2016 at 21:58.
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Old 18th July 2016, 10:37   #5
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Thread moved from the Assembly Line (The "Assembly Line" Forum section) to the Motorbikes Section. Thanks for sharing!

Last edited by GTO : 18th July 2016 at 10:37. Reason: Bump
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Old 18th July 2016, 12:56   #6
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Default Re: Honda Activa DIY: Headlight upgrade and LEDs for indicators + tail lamps

Anurag, small and Subtle mods make a world of a difference,wonderfully executed. Many thanks for sharing.I too am in the process of installing LED bulbs on my Cl500 and so far have installed bulbs on the speedo. Can you please share the links from where you procured the-
1-LED turn indicators.
2-Solid state Relay
3- Philips xtreme vision rear stop light bulb.
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Old 18th July 2016, 14:56   #7
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Default Re: Swapping the Headlights

Quote:
Originally Posted by a4anurag View Post
The OE bulb was Okay but the lights were spread all over the road (read scatter) so visibility was poor especially when in Low Beam. On the other hand the high beam was sharp and pointing upwards towards the trees.
Dear a4anurag,

I'm not sure if activa has this headlamp leveling screw (screw number 5 that holds the headlight cowl) but if does, did you try to adjust the headlamp?

I had same issue with my splendor, poor visibility in low beam and high beam pointing upwards into trees and sign boards

If the headlamp position is higher than normal, the light beam points higher. This is the reason for poor visibility in low beam and light beam pointing towards the sky in high beam.

The leveling screw is backed with a spring, so when the screw is loosened the spring pushes the headlamp upwards and similarly when tightened the headlamp points downwards which in turn brings the light beam downward.

Best Regards,
T-Bone
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Old 18th July 2016, 15:01   #8
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Quote:
Originally Posted by T-Bone View Post
I'm not sure if activa has this headlamp leveling screw (screw number 5 that holds the headlight cowl) but if does, did you try to adjust the headlamp?
Regarding the leveling screw, It is very much present Sir.

I have kept at the lowest level currently post the reflector change. Will be swapping bulbs to narrow down on one.

Leveling screw is just above the Screw No. 5 not sure if it is visible in the pictures.
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Old 18th July 2016, 15:48   #9
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Quote:
Originally Posted by rakesh_r View Post
Anurag, small and Subtle mods make a world of a difference,wonderfully executed. Many thanks for sharing.I too am in the process of installing LED bulbs on my Cl500 and so far have installed bulbs on the speedo. Can you please share the links from where you procured.
Thank you buddy. Happy you liked it.

Here you go,

1) BAU15S 7507 PY21W CREE LED Bulbs For Front Turn Signal Lights

http://m.aliexpress.com/item/3223840...bilesitedetail

2) Speedwav Scooter Indicator Flasher Relay-Honda Activa

https://www.amazon.in/dp/B013K6K0BE/..._2TkJxbN4T7M3D

3) Philips Xtreme Vision LED P21/5W LED


https://www.amazon.com/gp/aw/d/B00HW...RHJCDQQTY2DQQH
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Old 8th September 2016, 22:26   #10
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Default Re: Honda Activa DIY: Headlight upgrade and LEDs for indicators + tail lamps

Nice thread brother, I learned a lot by reading it. I recently brought a white activa 125 for my sister, and the headlight performance is awful, So looking for an upgrade now.

How is the performance Philips Rally Moto Halogen 40/40W.? Is it plug and play for the activa? Where can we find it, seems like it's no that of popular bulb.
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Old 8th September 2016, 23:04   #11
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Quote:
Originally Posted by Mr.ASG View Post
How is the performance Philips Rally Moto Halogen 40/40W.? Is it plug and play for the activa? Where can we find it, seems like it's no that of popular bulb.
I am yet to install the Philips on my scooter. I am hardly getting time to take it out. It is lying idle at home. :(

Shall definitely update ASAP. Apologies!

The bulb is difficult to source, I got mine from a BHPian who couriered it from Kerala.
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Old 20th January 2017, 11:32   #12
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Default Re: Honda Activa DIY: Headlight upgrade and LEDs for indicators + tail lamps

Quote:
Originally Posted by a4anurag View Post
Shall definitely update ASAP.
Hi Anurag, I'm wondering if you did try the Philips Bulb. I am in search of one. Would be nice to know your experience. Thanks
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Old 21st January 2017, 22:50   #13
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Default Re: Honda Activa DIY: Headlight upgrade and LEDs for indicators + tail lamps

Quote:
Originally Posted by madhavgpai View Post
Hi Anurag, I'm wondering if you did try the Philips Bulb. I am in search of one. Would be nice to know your experience. Thanks
Sir, to be honest, i have not got the time to replace the bulb as yet.

I have hardly been taking the scooter out. It is standing idle under cover let alone night rides.

Apologies for the delay.
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