It is not there is CD 100 so it is not mentioned in manual. It is present in Y2k bikes i.e splendor, joy, passion, e.t.c.

Regarding the use of the resistor, then let me add, it is there for a purpose, its because it dissipates heat when lights are off. regarding why above_all bike ran without problem, then let me tell you it was mere co-incidence that it didn't create problem.

CBZ, KARIZMA, all have bigger rectifier which dissipates heat through heat sink, but our bikes RR unit is very small and is not so big. So hero honda has cleverly designed this resistance which will use the complete chassis as heat sink and also RR unit will last long.
Have you seen any splendor, passion or joy ever have problems in RR. But the new bikes have problem. So by isolating the heat dissipation from RR they have prolonged its life.

So the thing is same either RR unit should have large heat sink or like our splendor heat dissipation is somewhere else.

And i have seen RR unit damaged because of faulty resistor in bikes.

Simply great ! Every thing I learn about this splendor amuses me. Every problem has been solved cleverly and not over-engineered unlike other products which gives these bike unmatched reliability and peace of mind .
The new splendor pro and Passion Xpro are the best in class. It has better lights,self start,disc brakes and powerful vertical engine in Xpro.

In a way I feel that the main reason hero(or even others except bajaj) has not used Full DC lights on their lower cc bikes is because :
1.It is reduces the load on battery and increases its life.
2.Smaller alternators can be used which provide sufficient illumination at higher revs,
3.To prevent battery drain while idling with HL ON,bigger alternators will be needed to power it Up but causes parasitic load on the engine thereby decreasing performance and mileage.

After few days my mama called me, it was almost completed and threading was remain, i went there so that it can be checked if its going in or not.



So this is how i got holder & puller made.

I also went to market to search for compression gauge jugaad, but couldn't find it anywhere. I entered one shop who kept machinery tools. He was having gauges and all, but not the thing which i wanted. No one didn't even know what is compression gauge.

If i tell to my mama, he will easily make it, but i don't want to waste their time anymore.

^^ good job. i would suggest this thread (though 'just' 184 pages old) for anyone who wants to learn something about bikes.
in most other threads, people are just changing oil and redlining or busy running in their bikes.

Good DIY...Nothing like making tools with your own hand on a lathe and doing welding...
Did you take Anti Tetanus injection after the injury ? It is safer to do it since one doesn't know the contamination at the workshop...Whenever you handle
Tools or equipment , which you are not used to, the first thing to see is the condition of the tool and safe guard against injury...
In the pic with you grinding the end of the metal , you are holding the bar against the grinding wheel in wrong way...if the grinding wheel gets to have higher friction, or the metal slips, then the metal will be dragged down along with your hand,,,this will lead to your hand hitting the rotating grinding wheel and resulting in a bad injury...

Safety first..
Good luck..

P.S. Your hand shows that you are an adamant person with a will of his own.....

Good DIY

But please warn your MAMA that the tools in his shop are not that safe. The drill bits are rust in the Shank area( Locking area). This could lead to failure during drilling process. The nuts, washers and bolts used in the bench grinder is extremely rusted. Since bench grinder's RPM are very high compared to conventional machines. The rusted parts can fail which will be catastrophic if not attended to. These are just just my observations as I am working in an automobile ancillary manufacturing industry. Please be safe rather than regretting it later.

Cheers

Mathews

Actually i didn't saw that nail my hexo, while cutting i was completely focused on a cutting area if its going straight. I was so focused that when it hit my hand for the first time i didn't feel anything when it hit the second, then my brain sensors came into react & detected the pain.
I use that hexo very often, so when i next time use it, i will be remember that thing. and will first remove it.

Yes i know i hold the bar in a wrong way, because i was wanted to take pic with those sparking light coming out and as i am alone here so there was no one to take the pic. I was too worrying if that slips, but i was holding very light. I took the pic with my right hand.
And i glad i didn't hit that wheel, BTW, i am having this machine from more than 24+ years, and i started using it from or before std-9 in school days. from about 8~9 years.
and i love this machine. It does jobs in few minutes and saves lots of time. I'm also having polishing wheel which can be fit this.

My MAMA is working in his shop from 30 yeas. I wasn't even born that time. So i myself can't say anything to him because he is much older and experienced in this field that i am nothing towards him. He had lot of work to do everyday, he stays very busy with heavy work load. Sometimes he is not able to do some of his household work then how he will get time to keep those stuffs safe. He didn't care even in scraping those.
You haven't seen the workshop, the workshop is very very big. It may be a double the size of two marriage parties hall. All you can say he had spent his whole life in this field.

See there is the problem. I am sure and I know people like your MAMA for over 10 years. I have learnt and learning so many things from people like your MAMA. They know each and every bit of the machinery they have got and are very experienced on these machines. But the problem is that these people are so very involved in the work at hand that they forget the basic safety requirement in every machine.

Just an example from a shop floor more or like your MAMA's shop.

This is just an illustrated photo. Even in this photo the operator is not using Safety googles which is provide in the wooden box just above the switch board. This guard which is marked in the photo is a very very important safety equipment which is essential for all bench grinders. The reason being, if the wheel/tool breaks due to high pressure or crack in the wheel will prevent it from hitting the person doing the job.

I Know that your MAMA knows all that I am telling. But time plays a big factor here. But it is no surprise that he avoids all these safety factors as it will take some of his precious time to take care of these factors. But we as a rider know the value of safety equipments. We know wearing a helmet/knee pad/elbow guard all takes time and are difficult to some people due to heat and other discomforts. But we never allow safety to take a back seat. And we know the benefits of these safety equipments and there are so many testimony from riders how they have saved their life's each and every time.

I think it is your responsibility to request (Not advice) your MAMA to follow some safety in the work shop. I know he will tell you a big story about how he has no time even to run the daily show in his shop. But there is no point in building a big empire and .....

Please take it very very seriously. I know in one day it is not possible But if you really love your MAMA and are looking out for his safety I think you can definitely peruse him to do the needful.

Cheers

Mathews

@ Excellent work ! This is REAL DIY !
The final puller seems to be crafted much better than the original. Show this to your mechanic and I am sure he will beg you to make another one for him also.
Consider making clutch holder and a valve compressor also,It is very easy to make when compared to the magneto puller.If you want the dimensions of valve compressor,I will post it.
Rough approximate of how much it would have costed a customer to get this work done by your Mama(Including material) ?

I wish to have air compressor,air tools and a welding machine someday in my life so that I can.................

Thanks, i've bought clutch holder today, and there is no need of valve compressor to me, i can fit the springs alone using ring wrench. Yes its bit difficult to do alone, but its not impossible also. BTW, who is going to open everytime, once fitted then no need to see for the next 15-20k kms.

Dont know how much that have costed, but the material on a old puller is soft metal, and that cost Rs.40/kg and that EN18 cost between Rs.70~80/kg, and its double the weight than old puller.

I love that machine where puller is being made. Its a great machine and can perform great stuffs. My mama have 5 of them, and 4 big driller machines. I will fit that machine in my garage once i have my own house.

@ Paul you still haven't answered my query...did you take the Anti Tetanus Injection.? don't postpone it..you should take it within 24 hours of the injury.

Secondly it is EXACTLY what you described as holding camera in one hand and the job against the Grinder in the other , which causes bad injuries in work...When you are working with power tools you can't be too careful...and be attentive in what you are doing.
Good luck, Do things in a Safe way..

Gave my splendor for service and picked it up late in the evening yesterday.
Today morning, while driving to office, i noticed a change in the engine sound.
While raising the throttle (slight acceleration), there is a kich-kich-kich-kich sound along with the usual engine note. This noise goes away of releasing the throttle (ie, decelerating).
I have never noticed sound this earlier during my entire ownership experience. Iam very sure it has started after giving it for service.
What could be the cause? Is it serious enough for me to take it back to the service center?


Thanks in advance.

The sound might be due to loose chain. Check whether it is coming from the chain. If so just tight the chain at a local mechanic. Cheers

Mathews

The noise is not from the chain area. More from around the engine block area.
Went back to the service center. They diagonised it as a leakage in silencer around the area below the engine block. Iam not an expert on this. But the leakage appears to be directly under the engine block where the silencer is attached to the block. The mechanic started the bike and asked me to place my palm directly beneath this area and i could feel hot air blowing down. He said silencer might have developed a crack and needs to be welded (cost around 200/- bucks) and also 'head gasket' (not sure what it is) should be replaced (another 250/- bucks).


To double check on this, drove down to another Hero Motors A.S.S and got their opinion on the problem. Their primary diagnosis seems to be similar. The mechanic there said it could also be that a nut around the same area seems to be loose and needs tightening. Since that area was too hot, he has asked me to bring it tomorrow. If the nut tightening solves the issue, iam saved. Else iam looking at a silencer crack/welding job.


Iam sure folks at the service center where the bike was serviced mis-handled it and caused the crack,since the bike was perfect when i gave for service. There were absolutely no unnecessary engine noise at all.

Cracks forming near silencer entry point is common .Get the silencer removed and take to a gas welding guy and he will take less than Rs.50/- no need of any gasket ,all that is cheating .I have done this more than4 times on my splendor.