Emergency Honda PCX Roadside Tools & Instructions
Posted: Thu Apr 04, 2013 9:04 am
I'm heading off on a trip from Thailand to Cambodia (I live in Thailand) and I want to be able to take care of the two things that could strand me in the middle of nowhere. Flat tyres and broken drive belts.
So ... I compiled a list of all the tools needed plus instructions and videos ... copied it all to my smartphone (including vids) and packed the tools under the seat. Ready to go! I'm strapping a spare tyre to the back of the top box as well.
If anyone can see any mistakes ... can you let me know? Anyway, I thought I'd share it here as it may be useful to someone.
Honda PCX Roadside Tools & Instructions
For tyre repair, wheel removal, tyre change, belt/roller change
Change Drive Belt/Rollers
Socket Wrench
Phillips Head Screwdriver
8 mm socket
10 mm socket
22 mm ring spanner
Variator Holder
Hammer?*
Spare Drive Belt/Rollers
How to Video
http://www.youtube.com/watch?v=q8c1njzv69U
Belt
1. Remove 10 mm bolt in lower plastic skirt near kickstand.
2. Pull up and remove rubber foot rest tread.
3. Unscrew the six screws along the foot rest. (Phillip's Head)
4. Remove lower plastic skirt (see video)
5. Remove the three 8mm bolts from the variator cover. Remove cover.
6. Remove the nine? 8mm bolts from the gear cover. Remove cover.
7. Insert variator holding tool
8. Remove 22mm variator nut. (Hammer too?) (Or use an impact driver if at home)
9. Remove the round outer variator cover.
9. Remove belt/Change belt
10. See steps 6-10 below (Rollers)
Rollers
1. Tuck belt out of the way.
2. Remove cylindrical spacer from centre of variator.
3. Remove inner variator cover. (Careful not to drop the rollers everywhere)
4. Replace rollers.
5. Replace inner cover with rollers, spacer and outer cover.
6. Put belt around variator shaft.
7. Whilst pinching the belt together in the middle, replace outer variator cover and 22mm nut.
8. Start engine (on stand) and test.
9. Replace all the other stuff you took off in reverse order.
10. Ride to pub.
Remove/Change Rear Wheel
Socket Wrench
10 mm socket
12 mm long reach socket
14 mm socket
24 mm ring spanner
Hammer?*
How to Video
http://www.youtube.com/watch?v=kKGRtcZY1q0
1. Remove Exhaust cover (10mm socket)
2. Remove 2 rear exhaust nuts (12mm long reach socket)
3. Remove other 3 exhaust nuts (14mm socket)
4. Remove exhaust.
5. Loosen the central wing nut (24mm spanner)*+Hammer?
6. Remove shock absorber nut (12mm socket)
7. Remove 2 swing arm nuts (14mm socket)
8. Remove swing arm.
9. Remove splash guard (10mm socket)
10. Remove wing nut and wheel! (24mm spanner)
Tyre Repair
Pliers
Tyre Plug Kit
Cutter/Knife
12v Pump
How to Video
http://www.youtube.com/watch?v=fpmxWY4I8kQ
Changing Tyre
3 tyre irons
3 rim protectors
Windex
Rag
Spare tyre
How to Video
http://www.youtube.com/watch?v=anyY0UO5gqk
So ... I compiled a list of all the tools needed plus instructions and videos ... copied it all to my smartphone (including vids) and packed the tools under the seat. Ready to go! I'm strapping a spare tyre to the back of the top box as well.
If anyone can see any mistakes ... can you let me know? Anyway, I thought I'd share it here as it may be useful to someone.
Honda PCX Roadside Tools & Instructions
For tyre repair, wheel removal, tyre change, belt/roller change
Change Drive Belt/Rollers
Socket Wrench
Phillips Head Screwdriver
8 mm socket
10 mm socket
22 mm ring spanner
Variator Holder
Hammer?*
Spare Drive Belt/Rollers
How to Video
http://www.youtube.com/watch?v=q8c1njzv69U
Belt
1. Remove 10 mm bolt in lower plastic skirt near kickstand.
2. Pull up and remove rubber foot rest tread.
3. Unscrew the six screws along the foot rest. (Phillip's Head)
4. Remove lower plastic skirt (see video)
5. Remove the three 8mm bolts from the variator cover. Remove cover.
6. Remove the nine? 8mm bolts from the gear cover. Remove cover.
7. Insert variator holding tool
8. Remove 22mm variator nut. (Hammer too?) (Or use an impact driver if at home)
9. Remove the round outer variator cover.
9. Remove belt/Change belt
10. See steps 6-10 below (Rollers)
Rollers
1. Tuck belt out of the way.
2. Remove cylindrical spacer from centre of variator.
3. Remove inner variator cover. (Careful not to drop the rollers everywhere)
4. Replace rollers.
5. Replace inner cover with rollers, spacer and outer cover.
6. Put belt around variator shaft.
7. Whilst pinching the belt together in the middle, replace outer variator cover and 22mm nut.
8. Start engine (on stand) and test.
9. Replace all the other stuff you took off in reverse order.
10. Ride to pub.
Remove/Change Rear Wheel
Socket Wrench
10 mm socket
12 mm long reach socket
14 mm socket
24 mm ring spanner
Hammer?*
How to Video
http://www.youtube.com/watch?v=kKGRtcZY1q0
1. Remove Exhaust cover (10mm socket)
2. Remove 2 rear exhaust nuts (12mm long reach socket)
3. Remove other 3 exhaust nuts (14mm socket)
4. Remove exhaust.
5. Loosen the central wing nut (24mm spanner)*+Hammer?
6. Remove shock absorber nut (12mm socket)
7. Remove 2 swing arm nuts (14mm socket)
8. Remove swing arm.
9. Remove splash guard (10mm socket)
10. Remove wing nut and wheel! (24mm spanner)
Tyre Repair
Pliers
Tyre Plug Kit
Cutter/Knife
12v Pump
How to Video
http://www.youtube.com/watch?v=fpmxWY4I8kQ
Changing Tyre
3 tyre irons
3 rim protectors
Windex
Rag
Spare tyre
How to Video
http://www.youtube.com/watch?v=anyY0UO5gqk