Repair Manual, Maintenance & Inspection Scooter Honda SH 125

One day my dad called me, "You Tobias, the scooter does not turn off anymore, man has to push him on at the traffic lights, can you please repair him? I need him tomorrow." Since my counter question, if I was a workshop, was answered with "yes", I had to accept the matter for better or worse. First of all, I went to the Hondawerkstatt. There they wanted to disassemble everything for half an hour before they could submit me a quote for the repair. The next free appointment to be in a week. However, as my father needed the scooter again tomorrow, I decided to get my hands dirty again. After I screwed down the lid of the variator gear box (cool word or?), The V-belt came out.
With the engine running, I now noticed that the belt is running so fast even at idle speed that the centrifugal clutch (rear drum) is constantly responding. The defect had to lie on the variomatic rollers. These are according to an exploded drawing of in the front drum. The next challenge was to unscrew the variator without a special tool or blocking tool or Varioblocking tool, also known as Variotool. The thing is just as awkward as its name. For this I put two sturdy screwdrivers in the intended to hold holes. Then I used a tire lever to prevent the drum from spinning while loosening the nut.
After loosening the nut, the variator was easy to pull off the axle.
At the 20x14,8 and 11,5g heavy Vario Weights (with the SH 125i with ABS 20X15 16g weights are installed since 2013, the Honda SH 300i are original 19g weights in it, everything else is tuning), which are usually also coated on the side of plastic, were visible after only 12 tkm strong traces of abrasion. Also on the movable pulley, which unfortunately only made of cast aluminum and not made of harder material.

The installation of new wheels for 15.- Euro as well as a little later also the installation of a new variator for stately 71.- Euro was exactly the other way around than the expansion. After the drum was attached again, I started the engine, which automatically tensioned the V-belt. In order to be able to close the variomatic lid again without causing the gasket to fall out, I attached it to the lid with adhesive.
Because I already had dirty hands, I did another inspection, blew out the air filter and changed the transmission oil (SAE EP 80W-90). The new gear oil I filled with the help of a syringe.
Then I also changed the engine oil. 5 liters of 15W40 engine oil are available at Real for 12.- Euro. Update: Now my machine runs smoothly for over 10,000 km. For this price you do not even get a liter in many workshops. See also Frontal21. It does not always have to be branded oil. An oil filter does not have the scooter, only a sieve, which you should remove and clean. In order to catch the old oil without the main stand in the way, I carefully leaned the scooter against a wall. During the subsequent test drive, the scooter went as well as usual.
Some time later, the rear tire had reached its legal limit of 1.6mm tread depth and had to be replaced. To be able to remove the rear wheel, it was necessary to build the exhaust first. The screws on the manifold can be solved by first removing the cover in the footwell below the seat.
Then I set the left spring harder so that it carries the weight of the scooter while I released the right damper of the swingarm. Then I was able to remove the left, rigid rocker and the fender.
Now the wheel could easily be pulled off the axle and taken to the tire dealer.
As long as the wheel was removed, I checked the brake pads of the rear brake. The installation of the rear wheel was exactly the other way around than the expansion.
On request, I also connected an oscillating signal transmitter with the help of two diodes as Stromdieb to the two front indicators.
Now my father is reminded by beeping that the turn signals on the scooter do not automatically switch off again as in the car.
For installation, the front panel had to be removed together with the main headlight. Underneath was the radiator and the horn of the scooter.
Since the use of the original beeping horn is already almost embarrassing, I exchanged the same against the horn of a Honda Transalp PD06 with much lower sound. A little later it was time for new brake pads on the front disc brake. In order not to damage the brake caliper seal (brake caliper) when gently pushing back the brake pistons, it was necessary to carefully clean the brake pistons as well as the brake carriage bolts and grease them to prevent corrosion. The brake pistons must not jam but must be able to automatically re-engage when releasing the brake lever. The brake system is a vital component. If you do not believe you know what you're doing, ask a mechanic for help. Everything you need to know about scooters can also be found in a repair manual. All statements without guarantee.