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Hero Honda CD 100 1994: Restoration

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  • Hero Honda CD 100 1994: Restoration

    My dad owns a 1994 Hero Honda CD 100 Deluxe, black. Has about 84,504 kms of lifetime running and had been lying dormant in the garage since 2017.

    Now, he used it quite a lot for the past 24 years or so before leaving it for dead. The bike was repainted back in 2004 (Black). It has all original parts (mudguards, saree guard, leg guard and mirrors) with zero scratches or bends. Such was the care taken of it. 2 years back he forgot to change the engine oil and the bike ran post 3000kms and was totaled in the middle of a highway. It was towed and then a popular mechanic did a rebore work of the old engine and changed the crank shaft. The bike was running again but had starting issues due to improper compression and the kick would rebound a lot of times before starting up. It was like wrestling up with it. Also, the spark plug would accumulate carbon & deposits, often and within a ride of 10-15kms (fixing the new guides, rockers and valves later in January sorted this issue for me).

    Nevertheless, the bike was too short in height for me to ride as a result never touched it. I'm frequently used my bro's Unicorn or my roommate's Hornet depending on where I was during college days. Later I purchased a Splendor Pro 2015 for city commutes. Now, my dad uses my bike most of the time and I don't feel like taking Unicorn into bumper to bumper traffic due to the heavy weight. The riding position of Splendor turned out to be a worry due to my shoulder issues. The rider triangle on CD seems comfortable.

    Took the plunge and finally started on the restoration project. This bike has been neglected a lot and took space in the garage. I decided it was enough and time had come to get this thing working.

    Here's a list of things I've had planned to properly restore the bike:

    1. Get everything dismantled and have the flame, panels, tank and body parts painted. Gonna get a new chain cover, side stand and get the bolts nickeled.

    2. Get a proper wiring harness. The current one is all messed up and the indicator rectifier seems blown. Turning indicators don't work.

    3. New Fork pipes for front shocks. The old ones are leaking.

    4. Front Wheel Drum plate. There's a crack on it as result the cable & pinion won't fit. It's a 110mm plate. Checked at every spares shop. Can't find it. Would appreciate some suggestion here. I've been asked time and again to go with the 130mm one from Splendor. It would require me changing the hub, the spokes etc.

    5. Getting a new lockset. Minda set planned so far.

    6. Fill fresh damping oil on both front and rear shocks.

    7. New Brake Shoes on both wheels.

    8. Attempt fitting the newer kind of switchgear from Splendor.
    Attached Files
    Last edited by Bismaya; 02-14-2019, 05:32 PM.
    Honda Hornet Owners WhatsApp Group - https://chat.whatsapp.com/Ip70mWBQw3p2wDklME2xPK

    [My Motorcycles]


    2016 - Sold: Honda Unicorn 150
    2017 - Suzuki Shogun & Splendor Pro
    2019 - Honda xBlade Non-ABS (2018)

  • #2
    Re: Hero Honda CD 100 1994: Restoration

    Thread approved.

    Comment


    • #3
      Re: Hero Honda CD 100 1994: Restoration

      Hi [MENTION=95957]Bismaya[/MENTION], I have a 1992 CD100SS which is running well, but needs some work on the engine.

      I dug through old posts of the stalwarts-
      1. Yes, it's better to get a new one.
      2. USHA was recommended by Sibun, Shoeb and other senior members (sorry, forgot their names), so yes, you could go for USHA.
      3. I'm 6', the bike is short for me too, but I'm not sure what to do for this.
      4. Is the suspension of the deluxe different from that of the SS? I'm not too sure as I have not observed work being done on my SS, but I have observed work being on my friend's deluxe.
      6. These will be too low for the bike I guess. I have seen a restoration where the owner used a Yezdi/RE handlebar which was wider and slightly flatter.

      [MENTION=37035]ashwinprakas[/MENTION] [MENTION=28527]sibun[/MENTION] [MENTION=43108]shoeb2015[/MENTION] [MENTION=29030]Pinaki[/MENTION] will be able to help.
      Last edited by Shashank K R; 08-22-2018, 02:25 AM.

      Comment


      • #4
        Re: Hero Honda CD 100 1994: Restoration

        Originally posted by Shashank K R View Post
        Hi @Bismaya, I have a 1992 CD100SS which is running well, but needs some work on the engine.

        I dug through old posts of the stalwarts-
        1. Yes, it's better to get a new one.
        2. USHA was recommended by Sibun, Shoeb and other senior members (sorry, forgot their names), so yes, you could go for USHA.
        3. I'm 6', the bike is short for me too, but I'm not sure what to do for this.
        4. Is the suspension of the deluxe different from that of the SS? I'm not too sure as I have not observed work being done on my SS, but I have observed work being on my friend's deluxe.
        6. These will be too low for the bike I guess. I have seen a restoration where the owner used a Yezdi/RE handlebar which was wider and slightly flatter.

        @ashwinprakas @sibun @shoeb2015 @Pinaki will be able to help.
        Thanks for the words. Ashwin and I talked about this over PM. Also, I would like to see some pics of your CDSS, if you've restored it.
        Honda Hornet Owners WhatsApp Group - https://chat.whatsapp.com/Ip70mWBQw3p2wDklME2xPK

        [My Motorcycles]


        2016 - Sold: Honda Unicorn 150
        2017 - Suzuki Shogun & Splendor Pro
        2019 - Honda xBlade Non-ABS (2018)

        Comment


        • #5
          Re: Hero Honda CD 100 1994: Restoration

          Originally posted by Bismaya View Post
          Thanks for the words. Ashwin and I talked about this over PM. Also, I would like to see some pics of your CDSS, if you've restored it.
          I haven't restored it as it was in a good condition when I started using it.
          I've just changed the indicators, headlight and clutch plates at a recent service. Also got the seat frame changed and the entire frame painted.

          But the bike doesn't accelerate like it used to before. Also the cradle and crash guard are bent from a hit by a car in my apartment parking (a senior citizen couldn't control his car and rammed into our CD100, which in turn rammed into our Activa and car). Front suspension alignment seems to be off after the hit as well.

          I plan to get it serviced after getting my new bike which is due next week. I've not found a good mechanic yet, will try Royal Motors as suggested by Divya Bhai.




          Last edited by Shashank K R; 08-22-2018, 03:02 PM.

          Comment


          • #6
            Re: Hero Honda CD 100 1994: Restoration

            @"Shashank K R"
            Is that a Ceat Secura F85 on the front tyre?
            Honda Hornet Owners WhatsApp Group - https://chat.whatsapp.com/Ip70mWBQw3p2wDklME2xPK

            [My Motorcycles]


            2016 - Sold: Honda Unicorn 150
            2017 - Suzuki Shogun & Splendor Pro
            2019 - Honda xBlade Non-ABS (2018)

            Comment


            • #7
              Re: Hero Honda CD 100 1994: Restoration

              Originally posted by Bismaya View Post
              @"Shashank K R"
              Is that a Ceat Secura F85 on the front tyre?
              Yes it is.

              Comment


              • #8
                Re: Hero Honda CD 100 1994: Restoration

                Went to a scrap dealer to find an old chasis and find one from CD Dawn. This very guy I went to, he is known for stacking up and refurbishing old frames and bike metals. While I forgot to take a photo of the frame out of excitement, but pretty sure it was this one. He quoted me a price of Rs 910 for it. I think I'll buy and paint it. Opinions?
                Honda Hornet Owners WhatsApp Group - https://chat.whatsapp.com/Ip70mWBQw3p2wDklME2xPK

                [My Motorcycles]


                2016 - Sold: Honda Unicorn 150
                2017 - Suzuki Shogun & Splendor Pro
                2019 - Honda xBlade Non-ABS (2018)

                Comment


                • #9
                  Re: Hero Honda CD 100 1994: Restoration

                  Took the plunge and finally started on the restoration project. This bike has been neglected a lot and took space in the garage. I decided it was enough and time had come to get this thing working.

                  28th November 2018:->
                  ------------------------
                  The new keihin carb which was fit on the bike prior to the neglect was never properly adjusted. The bike wouldn't start and there were issues of misfires and the compression was like really hard. What I did was use [MENTION=29030]Pinaki[/MENTION] 's carb cleaning guide and washed the carb and dried it to get rid of any air bubbles. Re-attached the carb and tuned the carb.

                  Now, the tricky part was to set the AFR. The cylinder had had a lot of unburnt carbon which was a result of inproper AFR setting and has short-circuited about 3 to 4 spark plugs since the last time the vehicle was properly running. Cleaned the existing plug and adjusted the carb using DIY guides from YT until I was satisfied that the setting was correct.

                  2nd December 2018:->
                  -----------------------
                  Opened the chain cover and cleaned it up. Lubed the chain and switch gear to make sure the chain wasn't going to be an issue. Purchased a small WD40 can and sprayed it on the necessary cables and switch gears. Opened up the rear brake drum and cleaned it. Had the side stand properly welded and brake rear lever set in correct position.

                  4th December 2018:->
                  -----------------------
                  The misfiring issue still persisted and it was time to take the bike to a good mech. Fortunately, I was helped by a local member here to take my bike to a good mech. The bike usually run about 5 to 6kms before misfiring and the plug got deposited with carb, inspite on proper AFR tuning. Mustered up courage and cold started the bike and took it to the mech who was recommended. This was a 9km journey and the bike didn't give much trouble. The cylinder head was opened up and de-carbonized. AFR was set again, a new spark plug from Champion was installed. The previous NGK plug was short really bad. Had the bike checked up for any leaks in tyre and the bike was ready to run normally.

                  5th & 6th December:->
                  -----------------------
                  The bike ran well and I covered over 30kms before one fateful evening on 6th Dec, the bike start broke off it's hinges off the crank and bent down. Had to push the bike 2kms to my home. The hard compression combined with 25 years of sustenance of the kick had really given out.

                  7th December 2018:->
                  -----------------------
                  The mech was nice enough to come to my place and check my bike for any issues. He asked for a day's time and had me procure a new kick from Splendor Plus (OEM). It cost about Rs 340.

                  8th December 2018:->
                  ----------------------
                  The new kick was fit and the hard compression was still a pain. I complained that I've seen people with really smooth kicks on their CD's. Owing to this, the mech opened up the head and checked for proper piston clearance. Thankfully it was well and I asked him to inspect the valves and cam for proper timing. It was nice idea to have it done as those had been the main culprits for engine issues. The old mech (whoever the dumbass was) had barely set it properly and the new valves were deposited with unburnt carbon. Had those cleaned and put back in. Cam was taken out and the chain timing along with magnet was adjusted. Finally the tappet was adjusted as well. Over 4 hours of working, the bike fired up like a new machine. It was once again enjoyable to ride. The fuel tank was cleaned to get rid of the age old fuel, rust and moisture. It was checked for any leaks or holes before being placed. I had a decent amount of fuel filled up and the bike was ready to be used.

                  To sum it up: It is currently in running condition like any other proper working bike. The only thing it lacks is the meter cable and the pinion which I'm unable to find in the city. The paintjob was bee washed up after 25 years on weathering and acid rains (there was a time when we had no parking and the bike was parked in acid rains; awful old days). Painting and coloring is the only thing left to be done to make the bike look like a brand new one.
                  Attached Files
                  Honda Hornet Owners WhatsApp Group - https://chat.whatsapp.com/Ip70mWBQw3p2wDklME2xPK

                  [My Motorcycles]


                  2016 - Sold: Honda Unicorn 150
                  2017 - Suzuki Shogun & Splendor Pro
                  2019 - Honda xBlade Non-ABS (2018)

                  Comment


                  • #10
                    Re: Hero Honda CD 100 1994: Restoration

                    15th January 2018:->
                    ----------------------
                    Decided to get major overhaul done to the bike. Took it to another good mech who had a reputation of restoring bikes nicely. Had the cylinder head, bore and crankcase entirely opened and inspected. The bore seemed fine and all the parts inside crankcase were good for the time being. The bore was brand new and hadn't run for 500kms at most.

                    The head needed a lot of work. The valves were worn out. The rocker arms were damaged and the guides were out of place. Took it to a good lathe guy and had the new guides installed. Purchased new valves, rockers, a tappet adjustment kit, packings, a new spark plug and a bottle of Castrol Activ 4T 20w40 to be filled. The headlamp housing had cracked over the last decade. Bought a new one from Lumax. The throw isn't adequate. Still not satisfactory. I think the old technology is to blame. Might have to use a better coil for some satisfactory results.

                    This was the last overhaul I've had done. A month has passed and I've commuted over 500+kms on it (locally). I use my Unicorn for highway rides and my dad keeps the Splendor for his purpose.
                    Honda Hornet Owners WhatsApp Group - https://chat.whatsapp.com/Ip70mWBQw3p2wDklME2xPK

                    [My Motorcycles]


                    2016 - Sold: Honda Unicorn 150
                    2017 - Suzuki Shogun & Splendor Pro
                    2019 - Honda xBlade Non-ABS (2018)

                    Comment


                    • #11
                      Re: Hero Honda CD 100 1994: Restoration

                      I never got to update this thread. I did an entire rebuild in 2019 for the most part. Wasn't a teardown and there was no cosmetic update. FC renewal is due really soon. Will think of doing a teardown rebuild (nothing major) and coloring once the fitness check is over.










                      Running the CD100 more regularly these days for local runs. Took it on a 74km trip last week. Still returns an average of 67.7kmpl. Carb rebuild is required. Sourcing parts for it.
                      Honda Hornet Owners WhatsApp Group - https://chat.whatsapp.com/Ip70mWBQw3p2wDklME2xPK

                      [My Motorcycles]


                      2016 - Sold: Honda Unicorn 150
                      2017 - Suzuki Shogun & Splendor Pro
                      2019 - Honda xBlade Non-ABS (2018)

                      Comment


                      • #12
                        Re: Hero Honda CD 100 1994: Restoration

                        Originally posted by Bismaya View Post
                        I never got to update this thread. I did an entire rebuild in 2019 for the most part. Wasn't a teardown and there was no cosmetic update. FC renewal is due really soon. Will think of doing a teardown rebuild (nothing major) and coloring once the fitness check is over.










                        Running the CD100 more regularly these days for local runs. Took it on a 74km trip last week. Still returns an average of 67.7kmpl. Carb rebuild is required. Sourcing parts for it.
                        Me too got my dad’s 1992 Hero honda CD100SS restored in 2019,it’s FC is due and has to be taken back to the original registered rto for the same.
                        Sourcing parts is easy as it’s a Hero Honda
                        Though quality of parts aren’t the best

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