Dio BSVI Service Manuval Pdf

Information Caring for Your Vehicle Exhaust Pipe and Muffler Aluminium Components When the exhaust pipe and muffler are painted, do not use a commercially available abrasive Aluminium will corrode from contact with dirt, kitchen cleaning compound. Use a neutral mud, or road salt. Clean aluminium parts detergent to clean the painted surface on the regularly and follow these guidelines to avoid exhaust pipe and muffler. If you are not sure if scratches: your exhaust pipe and muffler are painted, z Do not use stiff brushes, steel wool, or contact your dealer. cleaners containing abrasives. z Avoid riding over or scraping against curbs. Panels Follow these guidelines to prevent scratches and blemishes: z Wash gently using a soft sponge and plenty of water. z To remove stubborn stains, use diluted detergent and rinse thoroughly with plenty of water. z Avoid getting petrol or detergents on the instruments, panels, or headlight. 98

Storing Your Vehicle Storing Your Vehicle After removing your vehicle from storage, Information inspect all maintenance items required by the If you store your vehicle outdoors, you should Maintenance Schedule. consider using a full-body cover. If you won’t be riding for an extended period, Transporting Your follow these guidelines: Vehicle z Wash your vehicle and wax all painted If your vehicle needs to be transported, it surfaces (except matte painted surfaces). should be carried on a motorcycle trailer or a Coat chrome pieces with rust-inhibiting oil. flatbed truck or trailer that has a loading ramp z Place your vehicle on its centre stand and or lifting platform, and motorcycle tie-down position a block so that both tyres are off the straps. Never try to tow your vehicle with a ground. wheel or wheels on the ground. z After rain, remove the body cover and allow the vehicle to dry. NOTICE z Remove the battery (P. 61) to prevent Towing your vehicle can cause serious damage to the discharge. Fully charge the battery and then transmission. place it in a shaded, well-ventilated area. If you leave the battery in place, disconnect the negative terminal to prevent discharge. 99

You & the Environment You & the Environment down a drain or on the ground. Used oil, petrol, and cleaning solvents contain poisons that can Owning and riding a vehicle can be enjoyable, hurt refuse workers and contaminate drinking but you must do your part to protect the water, lakes, rivers, and oceans. environment. Information Choose Sensible Cleaners Use a biodegradable detergent when you wash your vehicle. Avoid aerosol spray cleaners that contain chlorofluorocarbons (CFCs) which damage the atmosphere’s protective ozone layer. Recycle Wastes Put oil and other toxic wastes in approved containers and take them to a recycling centre. Call your local or state office of public works or environmental services to find a recycling centre in your area, and to get instructions on how to dispose of non-recyclable wastes. Do not place used engine oil in the trash, or pour it 100

Serial Numbers Serial Numbers Frame number The frame and engine serial numbers uniquely identify your vehicle and are required in order to register your vehicle. They may also be required when ordering replacement parts. You should record these numbers and keep them in a safe place. Information Engine number 101

Information Fuels Containing Alcohol The use of petrol containing more than 10% ethanol may: Fuels Containing Alcohol z Damage the painting of the fuel tank. z Damage the rubber tubes of the fuel line. Some conventional fuels blended with alcohol z Cause corrosion of the fuel tank. are available in some locales to help reduce z Cause poor drivability. emissions to meet clean air standards. If you plan to use blended fuel, check that it is NOTICE unleaded and meets the minimum octane Use of blended fuels containing higher than approved rating requirement. percentages can damage metal, rubber, plastic parts of your fuel system. The following fuel blends can be used in your vehicle: If you notice any undesirable operating z Ethanol (ethyl alcohol) up to 10% by volume. symptoms or performance problems, try a different brand of petrol. Petrol containing ethanol may be marketed under the name Gasohol. 102

Catalytic Converters Catalytic Converters Follow these guidelines to protect your vehicle’s Information catalytic converter. This vehicle is equipped with a three-way z Always use unleaded petrol. Leaded petrol catalytic converter. The catalytic converter contains precious metals that serve as catalysts will damage the catalytic converter. in high temperature chemical reactions that z Keep the engine in good running condition. convert hydrocarbons (HC), carbon monoxide z Have your vehicle serviced if your engine is (CO), and oxides of nitrogen (NOx) in the exhaust gasses into safe compounds. misfiring, backfiring, stalling, or otherwise not running properly, stop riding and turn off the A defective catalytic converter contributes to air engine. pollution and can impair your engine’s performance. A replacement unit must be an original Honda part or equivalent. 103

Specifications J Main Components Displacement 109.51 cm3 (6.680 cu-in) Bore x stroke 47.000 x 63.121 mm (1.8504 × 2.4851 in) Overall length 1808 mm (71.2 in) Compression ratio 10:1 Unleaded petrol Overall width 723 mm (28.5 in) Fuel Recommended: 91 RON or higher Overall height 1150 mm (45.3 in) Fuel containing ETHANOL up to 10% by volume alcohol Wheelbase 1260 mm (49.6 in) Tank capacity 5.3 litres (1.40 US gal, 1.17 Imp gal) YTZ4/ETZ4/ATZ4L Minimum ground clearance 160 mm (6.3 in) Battery 12 V - 3 Ah (10 HR) A/T 2.55:1 to 0.80:1 Caster angle 27º 30´ Primary reduction 10.208 Final reduction Trail 72 mm (2.8 in) Curb weight 105 kg (231 lb) Specifications Maximum weight 174 kg (383.6 lb) capacity*1 Centre compartment 10 kg (22 lb) Maximum luggage weight*2 Front inner box 0.5 kg (1 lb) Luggage hook 1.5 kg (3 lb) Passenger capacity Rider and 1 passenger Minimum turning radius 1.96 m (6.43 ft) *1 Including rider, passenger, all luggage, and accessories *2 Includes the weight of the luggage and added accessories. 104

peci icati ns J Service Data Honda 4-stroke motorcycle oil API Service Classification SJ or higher, Tyre size Front 90/90-12 54J Recommended excluding oils marked as “Energy Conserving” Rear engine oil or ”Resource Conserving,” 90/100-10 53J SAE 5W-30,JASO T 903 standard MA or MB Tyre type (10W-30 only) Tubeless Front Engine oil After draining 0.55 litres Tyre air pressure (Driver only) capacity (0.6 US qt, 0.5 Imp qt) 150 kPa (1.50 kgf/cm2, 22 psi) Rear (Driver and passenger) After disassembly 0.75 litres 150 kPa (1.50 kgf/cm2, 22 psi) (0.8 US qt, 0.7 Imp qt) (Driver only) Transmission Oil After draining 0.09 litres Specifications 200 kPa (2.00 kgf/cm2, 29 psi) capacity After disassembly (0.10 US qt, 0.08 Imp qt) (Driver and passenger) Spark plug 250 kPa (2.50 kgf/cm2, 36 psi) 0.10 litres (0.11 US qt, 0.09 Imp qt) Spark plug gap MR8E-9 (NGK) Idle speed UR5DE0 (BOSCH) 0.8 to 0.9 mm (0.03 to 0.04 in) 1700 ± 100 rpm 105

peci icati ns J Bulbs J Torque Specifications Headlight SCV110F/FB ID 12 V- 35/35 W Engine oil plug 20 N·m (2.0 kgf·m, 15 lbf·ft) SCV110F/FB II ID LED 12 V- 21/5 W Engine oil drain bolt 24 N·m (2.4 kgf·m, 18 lbf·ft) 12 V- 10 W x 2 Brakelight/Taillight 12 V- 10 W x 2 LED Front turn signal Rear turn signal Position light Specifications J Fuses 20 A 7.5 A Main fuse Other fuse 106

Warranty Policy (Valid in India only) Honda Motorcycle & Scooter India (Pvt.) Ltd. In all such cases the decision of the respective Warranty Policy (HMSI) gives the following warranty in respect of manufacturer will be final and binding. vehicle “Dio” manufactured by them. HMSI shall not be liable in any manner to replace them though their dealers will give full Proper care and precaution has been taken to assistance in preferring such claims on their ensure the best quality in respect of the manufacturers. material and workmanship in manufacturing “Dio”. HMSI undertake no liability in the matter of consequential loss or damage caused due to HMSI would repair or replace at its discretion, the failure of the parts. Delay, if any, at the those part(s) found to have manufacturing repairing workshop in carrying out repair to defects during examination.This repair or vehicle shall not be a ground for extending the replacement of part(s) would be done free of warranty period nor shall it give any right to the charge at their authorised workshop, within a customer for claiming any compensation for warranty period of 36 months from the date of damages. sale or until the vehicle has covered 36000kms, whichever comes first. HMSI reserves the right either to repair or replace the defective part. Warranty claims in respect of proprietary parts Where a defective part can replaced by part/s like tyres and battery are warranted by their of alternative brand/s, which are normally used respective manufacturers and should be by HMSI in the course of manufacturing, HMSI claimed on them directly by customer. reserves the right to carry out the replacement by a part or parts of any such alternative NOTE: Battery Warranty is applicable from 21 brands. months from Date Of Charging at manufacturer or 18 Months from the Date Of Sale or 20000 107 Kms whichever is earlier.

WWarraarnrtyanPotlyicyP(VoalliidcinyIn(dViaalOidnliyn) India only) Warranty Policy This warranty and any claim arising there from Further this warranty is not applicable to: is subject to Gurugram jurisdiction only.  Any “Dio” on which any free and paid No claim for exchange or repair can be services has not been carried out, as per consider unless the customer: schedule given in Owner’s Manual. a. Ensures that immediately upon discovery of  1RUPDOPDLQWHQDQFHRSHUDWLRQVOLNHYDOYH the defect, he approaches any nearest DGMXVWPHQWFOHDQLQJRIIXHOV\\VWHPRUVXFK authorised dealer of HMSI with the RWKHUDGMXVWPHQWV concerned vehicle and enables him to remove and dispatch the part/parts  HMSI does not warrant normal wear and attributing to manufacturing defect to the tear items like Clutch Disc, Chain, Chain company. Sprocket, Wheel Rim (in case of misalignment and bent), Bushes, Fasteners, b. Produces Owner’s Manual in original, to Shims, Washers and Electrical Items like enable that dealer to verify the details. It Bulbs, Rubber and Plastic Components like must be expressly understood that claims Grommets, O-Rings,Bellows as well as forwarded directly to us by the owner/ Packings, Gaskets, Oil Seals and customer will not be entertained at all and Consumables like Fuel Filter, Air Cleaner such defective part/parts thus forwarded Element, Engine Oil, Grease, Suspension Oil by them will lie at our factory at their own and other items as specified by HMSI. risk, and this warranty shall not be enforceable.  Fasteners and clips which needs replacement during maintenance/service will not be covered under warranty. 108

Warranty Policy (Valid in India only) Warranty Policy (Valid in India Only)  If there is any damage to the painted not manufactured or recommended for use Warranty Policy surface due to industrial pollution or other by HMSI if in the sole judgment of HMSI, extraneous factors. such use prematurely affects the performance and reliability of the vehicle.  Any damage resulting from unavoidable natural disaster i.e fire collision, earthquake, 13. Parts of the vehicle that have been altered flood etc. or modified or replaced in unauthorised manner, and which in the sole judgment of  Any damage caused by exposure of the HMSI affect its performance and reliability. product to soot and smoke, chemical agents, bird-droppings, sea water, sea 14. The vehicle that has not been serviced by breeze, or other environmental HMSI authorised dealer as per the service phenomenon. schedule or which have not been operated or maintained in accordance with instructions  If there is any damage caused due to usage mentioned in the Owner’s Manual. of improper oil/grease, non genuine parts. 15. The vehicles used for any competition or  For two-wheelers, which have been usedfor race and/or for attempting to set up any any commercial purposes as taxi etc. kind of record HMSI reserves the right to make any changes in design or to add any  For maintenance repairs required due to improvement on the vehicle at any time misuse while driving or due to adulteration without incurring any obligations to install of oil, petrol or due to bad road conditions. the same on a vehicle previously supplied and sold. Also the conditions of this  Recommended fuel quality not used. warranty are subject to alteration without any notice.  Parts of the vehicle that have been subjected to misuse, accident, negligent 109 treatment or which have been used in conjunction with parts and an equipment

WWarraarnrtyanPotlyicyP(VoalliidcinyIn(dViaalOidnliyn) India only) Warranty Policy This warranty is entirely written warranty the authorized service center shall take such given by HMSI for “Dio” and no other corrective measures as may be necessary and person, including the dealer or its or his shall at its sole discretion replace free of charge agent or employee is authorised to extend such components of emission control system as or enlarge this warranty. are specified in schedule. This warranty is given in lieu of and excludes every condition or warranty whether A. Conditions statutory or otherwise not herein expressly 1. This warranty will be in addition to and run set out. parallel to the product warranty given by EMISSION WARRANTY the manufacturer and will apply to Subject to other terms of the warranty policy components as mentioned later. This and other conditions and obligations laid down warranty is applicable in Delhi, Mumbai, hereunder, the manufacturer certifies that the Kolkata and Chennai with effective from 1st components liable to affect the emission of the July 2001. Other places when included will gaseous pollutants in the vehicle in normal use be covered under warranty accordingly. despite the use to which it may be subjected, 2. The period of the vehicle’s emission warranty comply with provisions of rule 115(2) of the will be determined starting from the date of Central Motor Vehicle Rules, 1989 and further the vehicle sale. The period of time and warrants that if on examination by a service kilometers that are covered under the center duly authorized by the manufacturer, the provisions of warranty may vary but should vehicle is discovered to be failing to meet the not be less than the minimum warranty emission standard as specified in the said rule, period based on the vehicle category. 110 For a two-wheeler the emission warranty period is 30,000 kms or 3 years whichever is earlier.

Warranty Policy (Valid in India only) Warranty Policy (Valid in India Only) 3. Warranty claim for the components under of such examination will be final and binding. Warranty Policy Emission warranty will be admitted, for a If, on examination, a warrantable condition is prima facie examination, in the event of not established, the manufacturers will have failure of the vehicle to meet the emission to charge all, or part, of the cost of such standard as specified in sub-rule (2) of Rule examination. No 115 of the Central Motor vehicle Rules. 6. In case of a vehicle in which the 4. The warranty claim will be accepted only components covered under Emission after the examinations carried out by warranty, the manufacturer will replace, at Authorized Service Centers leads to a firm Authorized centers free of charge, the conclusion that none of the original settings components which are covered, but the have been tampered with and that the consumables as mentioned in Owner’s components has/have a manufacturing Manual shall be charged as per actuals. defect, and/or, that the vehicle is unable to meet the in-use emission standard, in spite 7. In case of a vehicle in which the of the vehicle being maintained and used in components covered under Emission accordance with the instructions in the warranty or the associated parts are not owner’s manual. independently replaceable on account of their being integral parts of a complete 5. The methods of examination to determine assembly, the manufacturer will have the the warrantable condition of the sole discretion to replace either the entire components will be at the sole discretion of assembly or by using some of the parts of manufacturers and or their Authorized the system through suitable repairs or service centers and results modifications. 111

WWarraarnrtyanPotlyicyP(VoalliidcinyIn(dViaalOidnliyn) India only) Warranty Policy 8. Any consequential repairs or replacement statutory authorities on account of failure of parts which may be found necessary to to comply with the in use emission establish compliance to in-use emission standards. standards, in addition to replacement of the parts covered under emission warranty, will 12. Emission warranty will be applicable not be made free of cost unless such parts irrespective of the change of ownership of the are also found to be in a warrantable vehicle provided all the conditions as laid condition within the scope and limit of the down in this document are met from the date product warranty. The consumables shall of original sale of the vehicle. be charged as per actual during such repairs or replacement of parts. 13. The emission warranty will be applicable only if: 9. All the parts removed for replacement under warranty will be the property of the a. Observes all the important instructions manufacturer. and any other precautions listed in the Owner’s Manual for use of the vehicle. 10 The manufacturer will not be responsible for the cost of transportation of the vehicle b. Under all circumstances uses lubricants to the nearest Authorized Service center or and fuel as recommended by any loss due to non-availability of the manufacturer. vehicle during the period of lodging of a warranty claim and examination by the c. Regularly obtains and carries out manufacturer and repairs. maintenance in accordance with the manufacturers guidelines and enters 11. The manufacturer will not be responsible the details in the Logbook. for any penalties that may be charged by d. Immediately approaches the nearest 112 authorized service center upon discovery of failure to comply with the

Warranty Policy (Valid in India only) Warranty Policy (Valid in India Only) in use emission standards in spite of h. Produces valid certificate of insurance Warranty Policy having maintained and used the vehicle and RTO registration. in accordance with the instructions in the Owner’s Manual and having carried 14. Conditions under which warranty is not out such repairs and adjustments as applicable: may be required with a view to establish such compliance. A valid ‘Pollution Under Control’ certificate as described in customer obligation D(6) e. Produces the ‘Pollution Under Control’ above is not produced. certificate valid for the period immediately preceding the test during A vehicle which is not serviced by which the failure is discovered, the test Authorized service center as per the service having been carried out either for schedule described in the maintenance obtaining a new certificate, or pursuant chart given in the Owner’s Manual. upon being directed by an officer as referred to in sub-rule(2) of Rule 116 of A vehicle, which has been subjected to the Central Motor Vehicle Rules. abnormal use, abuse, neglect and improper maintenance or has met with an accident. f. Produces the Owner’s Manual and Log Use of replacement parts not specified and book for verification details. approved by the manufacturer. g. Produces receipts covering maintenance A vehicle, or parts thereof, which has been of the vehicle as specified in the altered, tampered with or modified or Owner’s Manual from the date of replaced in an unauthorized manner. original purchase of the vehicle. A vehicle on which the odometer is not functioning or the odometer has been changed/tampered with so that the actual mileage cannot be readily determined. 113

WWarraarnrtyanPotlyicyP(VoalliidcinyIn(dViaalOidnliyn) India only) Warranty Policy A vehicle which has been used for 2. The emission warranty covers only competitions, races, rallies or for the compliance with the emission standard as purpose of establishing records. specified in the sub rule (2) of rule 115 of Examination by the manufacturers or his CMVR. It does not cover any other Authorized Service Centers of the vehicle performance of these parts or routine test shows that any of the conditions stipulated and consequent maintenance or in the Owner’s Manual with regard to use adjustments to establish compliance to the and maintenance have been violated. in use emission standard as applicable to A vehicle, which has been run on, the state, in which the vehicle is registered adulterated fuel, leaded fuel or lubricant or and is in use. fuel/lubricants other than those specified by the manufacturer in the Owner’s Manual The parts, which are covered under emission with regard to use and maintenance have warranty, are throttle body, fuel injector, been violated. ignition coil, muffler etc. SCOPE AND LIMITS NOTE: The emission warranty is applicable only 1. This emission warranty is in addition to product when a customer enters into emission warranty contract. warranty and shall run parallel to the product warranty for the vehicle as per the scope and limit described in the Owner’s Manual and all conditions described there in will apply in addition to those exclusively stipulated in this warranty. 114

Index A Owner’s Manual .................................................95 Index Tool Kit ..................................................................44 Accessories............................................................ 12 Crankcase Breather............................................ 79 B E Basic Operation Flow........................................ 14 Electrical Trouble................................................. 87 Battery.............................................................. 52, 61 Engine Brakes Number...............................................................101 Brake Lever Freeplay .........................................72 Oil.................................................................... 55, 68 Shoe Wear............................................................77 Starting ................................................................. 33 Braking....................................................................... 9 Environment........................................................100 Bulb Brake/Tail Light ...................................................89 F Front Turn Signal ................................................90 Headlight .............................................................. 88 Frame Number...................................................101 Position Light.......................................................89 Fuel Rear Turn Signal..................................................90 Gauge............................................................. 18, 20 C Recommended ................................................... 39 Remaining ..................................................... 18, 20 Caring for Your Vehicle....................................96 Tank Capacity...................................................... 39 Catalytic Converter .........................................103 Fuels Containing Alcohol ..............................102 Clock ......................................................................... 23 Fuses.................................................................. 55, 91 Compartment 115 Document Bag.............................................44, 95

Index G M Gasohol .................................................................102 Maintenance Fundamentals...................................................... 51 H Importance .......................................................... 47 Safety..................................................................... 47 Headlight Aim ......................................................80 Schedule ............................................................... 48 Headlight Dimmer Switch............................... 28 Helmet Holders ................................................... 42 Maximum Weight Limit..........................13, 104 High Beam Indicator .................................. 25, 26 Modifications........................................................ 12 Horn Button.......................................................... 28 O I Odometer ................................................ 18, 21, 95 Ignition Key ...........................................................94 Oil Ignition Switch .............................................. 29, 95 Indicators................................................................ 25 Engine ............................................................ 55, 68 Instruments........................................................... 18 P K Parking..................................................................... 10 Keys........................................................................... 94 Parts Location ...................................................... 16 Petrol........................................................11, 39, 104 L PGM-FI (Programmed Fuel Injection) Malfunction Indicator Lamp (MIL).........25, 84 Load Limits ............................................................13 Protective Apparel............................................... 8 Loading Guidelines ............................................13 R 116 Recommended Fuel......................................................................... 39

Oil........................................................................... 55 Switches.................................................................. 28 Index Refueling................................................................. 39 Removal T Battery................................................................... 61 Throttle.................................................................... 78 Battery Lid............................................................62 Tool ...........................................................................60 Centre Cover .......................................................63 Transporting Your Vehicle..............................99 Clip .........................................................................64 Tripmeter................................................................ 21 Front Centre Cover ............................................ 65 Troubleshooting.................................................. 82 Riding Precautions ............................................... 9 Turn signal indicators........................................ 26 Tyres S Air Pressure.................................................56, 105 Safety Precautions............................................... 8 Puncture ...............................................................86 Seat ........................................................................... 41 Replacing.......................................................56, 86 Serial Numbers ..................................................101 Shutter..................................................................... 31 W Spark Plug..............................................................66 Specifications .....................................................104 Warning Indicator On ......................................84 Speedometer ....................................................... 18 Warranty Policy.................................................107 Start Button .......................................................... 28 Washing Your Vehicle.......................................96 Starting the Engine............................................ 33 Starting the Vehicle........................................... 37 117 Steering Lock........................................................30 Storage Equipment............................................ 41 Storing Your Vehicle..........................................99