Re: Honda Activa niggles, issues and remedies As discussed in my previous post, the kick-starter jamming is a recurrent problem for the Honda Activa and almost all variator fitted gearless scooters. This is due to the fact that the variator chamber is dry sans any oil or lubricant and is seggregated from the gearbox that hosts SAE 30 gear oil. The variator rubber belt has to be dry and seggregated from oil of any kind. Hence, due to the space constraints the kick starter gears- primary and tertiary are thinner and are more fragile as compared to the heavy duty kick starter gears of geared bikes. My Activa is a 2003 mode,l having run some 24,000 kms as of now. It underwent a RTO fitness test is 2018.
Usually the tertiary gear of the kick starter gets a tooth mutilated due to constant use. It is the chief trouble maker. Hence, it is advisable to always have a good battery to activate the self starter on most ocassions and to use the kick-starter only rarely.
The scooter's bonnet has to be unfastened first of all. Use a good quality 12 size box spanner to unfasten the three nuts.
The variator cover has to be opened to understand the root cause of all trouble. The primary and tertiary gear teeth need to be checked. All but two nuts of the variator cover require a 8 size spanner to unfasten, whereas two of them require a 10 size spanner as shown in the picture/s below.
The processes are explained on the body of each picture. To unfasten the tertiary kick starter gear, please unfasten the tensioner that holds it to the variator cover. After the tensioner is unfastened, use a heavy duty screw driver to slide out the tertiary gear very gently from it's designated slot. Inspect it and if worn out, please replace. A new one costs Rs 180=00. The new one can be slided into the designated slot. Please apply grease on the gear teeth - both primary and tertiary. Grease application within the variator compartment needs to be the bare minimum, as spillage into the chamber may affect the rubber belt drive's performance.
If you have to replace the gasket packing, please buy a new one. A set of packings is available as shown in the picture/s. The old gasket can be taken out or if problematic, use of a screw driver mildly dismantles it. The new gasket cover can be affixed. There are two slots on the variator cover (other side affixed to the gearbox) one near the rear shock absorber and the other below the rubber hose, to hold the gasket cover in place before tightening all the nuts.
The variator cover needs to be placed on a newspaper to prevent scratches. Please also apply SAE 30m oil (minimum) to the kick starter lever after accessing it on the upper side of the variator cover. The hose pipe (air intake) on the fore side of the variator cover needs to be unfastened. The clip on the fore side can be unfastened with a cutting plier. It will have to be re-fitted using the same technique by using a cutting plier to hold the clip, loosen it and slide the rubber into it's slot on the scooter's chassis. There is no need to unbolt the kick-starter, air filter, or anything else other than the nuts as shown in the diagram to dismantle the variator cover. Down below on the variator cover, there are two variator cover nuts, that hold a clip, which in turn holds the rear brake wire firmly. Please take care to affix the clip, while re-fitting the variator cover after the job is done.
Last edited by anjan_c2007 : 18th July 2020 at 19:09.
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