Stealth - 2002 Honda Dio

Thread Starter #16


Honoured Member
Sep 11, 2009
January 2022 - H4 Conversion

Water seeps inside the assembly during rains, resulting in a blown bulb. Yet to find the leak point despite multiple leak tests.

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H4 bulb fits without much drama. Old BA20D bulb didn't have/need a retaining clip, so need some jugaad to fit the H4.

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Bought Osram Cool Blue Mega HS1 35/35 - ₹ 220.00

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Agni Ceramic Holder - ₹ 98.00

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Old headlight removed from FZ.

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Had retainer clip and rubber dust cap.

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Installed them and were perfect fit on Dio's headlight assembly.

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Dust cover also made for each other. Cut out the old connector and mated with the H4 holder.

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Plug-n-play harness.

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Cloth tape.

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One of the clips holding the light was missing.

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The clip.

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Bought two of them right away, ₹ 5.00 each.

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Cleaned up all the debris and wiped cleaned the reflector of any dirt. Lot of spotting and fading, might replace the assembly if available.

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Beam adjustment bolt under the headlight. Loosening it allows forward/backward movement of the assembly.

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Highest position.

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Lowest position.

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Corrected position.

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4300k temperature. Output is similar to old halogen bulb. Might upgrade to LEDs sometime in the future.

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Thread Starter #17


Honoured Member
Sep 11, 2009
January-February 2022 - Updates

Where it was parked for years.

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Found the Denso pair in my horn bin, removed from the Skids.

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Fiddled with the screw and back to life.

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Last horn relay from my bin, ran out.

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Quick DIY fuse holder. First time on a micro fuse.

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Plug and play horn wiring kit.

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Installed Windtones in a couple of Dios in their golden era, which was claimed to be impossible by all installers those days. There was just millimetre clearance from the body with precise bending of the clamp. These horns were smaller and flatter, so finding space wasn't hard. Would switch to Yamaha Fazer pair soon depending on availability.

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Shield mounting came off, so took it off.

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Made one more spare key. Lost the previous duplicate and spare. Just ₹80.

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Thread Starter #18


Honoured Member
Sep 11, 2009
March 2022 - Oil Change

Motul Scooter LE 10W30 - MRP ₹ 345.00, got for ₹ 280.00 from Ex-Jawan

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17 mm socket for drain plug and strainer.

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The strainer sits on the LHS. Drain plug almost exactly opposite in RHS.

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Strainer and parts.

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Around 550 ml drained. Exact a year and 2.5k km.

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A little extra to compensate the oil that's stuck in the bottle.

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Convenient long neck.

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Thread Starter #22


Honoured Member
Sep 11, 2009
August 2022 - Updates

Generation gap, Honda Leads.

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Used by my BIL and shocked to see it clocking 2.5k km in 5 months, otherwise doing yearly oil changes with extremely low odo clicks.

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Repeat!! Motul Scooter LE 10W30

MRP ₹ 365.00, got a discount of ₹ 75.00, from Ex-Jawan.

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Drained and filled.

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They deleted the long neck with new stock. It was very convenient with scooters.

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Gear oil change. Don't know when was the last change.

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Both 12 mm bolts.

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Bottom one is the drain bolt, common sense.

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Shut off the drain and fill through the top.

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Needs 120 ml. Filled some unknown brand using Yamalube bottle and a small piece of clear tube. Filled to brim and installed back the bolt. Done.

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Thread Starter #23


Honoured Member
Sep 11, 2009
September 2022 - Prep for Retest and Misc Updates

Washed the Dio at a car wash. Bought secondary air filter and exhaust gasket, ₹ 40.00 and ₹ 25.00 respectively.

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Engine compartment was dirty. Not cleaned in a long time.

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Oil vapour all over engine head.

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Cleaned up with TB cleaner.

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Location of secondary air filter

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Just a screw in the bottom.

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Bit dirty, but not damaged.

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The cover.

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New vs old.

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Soaked with oil.

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Installed, didn't resolve the issue. Symptom would be cold start issue.

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The suction line to the SA was cracked. Cut the cracked section and reinstalled. Sorted out.

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Exhaust was the only rusty part that needed fixing for the test.

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Nuts were in tricky position.

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Nuts covered in muck of ages.

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Shield removed.

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Just one more bolt and the exhaust came off after some shaking.

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Painted using Nippon Pylac heat resistant black

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Air filter box. Clueless as to how the muddy water got sucked in.

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Condition of old filter. No idea when it was last changed.

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New air filter - 17211KPL841 - ₹ 231.00

Updated Dio of the same generation came with viscous filter.

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New vs old. New one by Minda and old one Lumax.

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Replaced externally visible screws

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and bolts.

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Condition of the plug.

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Cleaned the engine bay.

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Bulb exploded again after wash.

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Replaced with a 35/35W bulb lying around.

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Removed the tint.

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All reset and ready to go for the exam.

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Thread Starter #24


Honoured Member
Sep 11, 2009
October 2022 - Completed 20 Years

Did the fitness test. Went with an agent, but after testing 3 vehicles in a row this year, understood that's a useless expenditure, and we can do it on our own without any fuss. Prep the vehicle, pay the fees, pick a date and present for inspection, simple.

Renewal of registration - ₹ 1000
Postal Fees - ₹ 45
Service/User Charge - ₹ 60
Total - ₹ 1105

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New number plates were installed for the process. Bought from Sagar again. This time ordered with holes as the clamps were of standard size. Paid ₹ 300.00 for a pair including shipping.

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