DIY: Did comprehensive maintenance on my 18 year old Honda Activa

Since I have all the tools to do the work to my satisfaction, I managed to download the parts catalog and made a list of parts required.

BHPian Ashtoncastelino recently shared this with other enthusiasts.

Just two days back, I had done several work on my 2005 Activa. Due to my packed college schedule I hadn't gotten time to address few issues like tappet leak, handle vibration at low speed, and carburretor cleaning which were annoying and long overdue. Luckily I managed to get 2 days holiday from college to do the work.

Since I have all the tools to do the work to my satisfaction, I managed to download the parts catalog and made a list of parts required. Sent the list to my Honda ASS and they had most of the stock with them but I good idea struck me, I noticed the Hero Pleasure old model had the exact same engine and thought why not get few parts which are available from them since they're relatively cheaper than Honda. Downloaded the Pleasure parts catalog and again created a list, Got majority of the parts from them and started dismantling the scooter in the evening around 3pm. Parts that were changed were:

• Clutch shoes
• Kicker ratchet
• Variator Rollers
• Kicker cover boot
• Ignition coil
• Spark plug (Bosch)
• Tappet cover gaskets
• Tappet cover bolt gaskets
• Secondary air filter
• Front nose moldings
• Helmet hooks in seat
• Seat rubber bushes

Parts cleaned and greased:

• Carbuerrator
• Air filter and its box
• Clutch assembly and its components
• Variator
• Self bendix
• Kicker
• Things that might need replacement or inspection:

• MY BACK

Photos of the work in no particular order:

Yes, I rode the scooter this way to the washing center to get a thorough wash.

Final look of the Scooter after all the work.

This is my daily workhorse and has never let me stranded anywhere. Have taken this on several long trips doing more than 300kms in a day without a hiccup. The FE I get is usually 45-49 in city and the highest achieved on the highway is 63kmpl with a pillion. I always ride in the economy zone hence the high Fuel efficiency. Current Odometer reading stands at 110495kms.

Regards,

Ashton Castelino

Check out BHPian comments for more insights and information.