^ I thought so too. Knowing this is a common problem is re-assuring.
One more thing i noticed in addition to increased engine noise is some thing like mis-firing noises emanating from the silencer. Phut.. Phut.. Phut.. some times loud and other times not so loud. Is this also seen/heard when there is a silencer crack/leak?

Technically speaking, why would a crack in silencer result in audible phut phut sounds while driving?

2002 splendor

Guys, i have a 2002 make splendor, it has been running quite bad lately (done 45000km). Here is the plethora of problems 1.There is black oil on spark plug no matter how i clean it , it comes back 2. Front shocks are not smooth like xtreme's , what can be done in this regard 3.It is necessary to change clutch plates as they may be at the end of their life 4. when hot engine gives ticking noise from head area , any insights would be helpful I am going for service to morow..so plz tell me the exact root of problems

Nothing removes oil and dirt better than kerosene wash followed by Hot detergent water wash.

Agreed, this is just an easier alternative for lazy people And Kerosine is also hard to source, what say about Diesel?

Same with diesel but kerosene works best IMO. I pay more than Rs.50 to get 1 ltr of kerosene that too after so many requests.So I keep this kero for some special uses and
For general washing/cleaning of spare-parts,chain ,engine area --diesel works great as a de-greaser.

I regularly clean the intake manifold and oil separator of my diesel car with diesel. Inter-cooler,Wheel bearings can also be cleaned with it.

Today I found out what this so called"Teflon" is .
It is a translucent paste(probably a lacquer)which looks like glue.
Today while at a friendly neighborhood spare parts retailer a person came to purchase 10 bottles of this product.

He gave me a free sachet and told me to use it on an old bike and see the magic ! Applied it on my dad's passion rear cowl and it did not even require buffing.
The shine was brilliant not long lasting,showed its true color after washing. Before selling this bike,I will apply it.

Now what is this ? It is a product called SPY Instant Polish which costs Rs.25 per bottle and Rs.7 per sachet.

Sorry psr ji for the late reply, i'm very busy from two days in overhauling my engine.
To be honest, i'll not lie to u,...and no i didn't took the Tetanus but i do have wash with anti septic (dettol). and it has become so many days so it had healed completely.
Yes its true that i hold that bar in one hand and camera in another. Otherwise i'm not going to hold that bar anyway, i did for a second just because of camera.

Splendors or any other hero silencers doesn't get cracked or rust. specially from head side. My bike is 9.5 years old and still running the factory silencer without any rust or crack. So its bolt are loose. Get it tight and it will go. If your head gasket is leaking than it should be opened otherwise not required.

as your bike have clocked 45k, then your block piston have worn and it smoking and therefore your spark plug is getting black oil.
You need to get re-bore your block with oversize piston (go for usha original cost 650) and you will need to give your head to the lathe so that their valve seat can be polished.
Front shocks needs oil change. and tricking noise is due to loose cam chain.
All you need to do is to take to a good mechanic, and he will do everything including head work. You don't need to be worry about anything. In this re-boring the total cost including parts and service can be more or less 2000rs. If rocker or cam shaft found worn then it will cost another 1000. Otherwise if things are not worn then it will be around 2000 (depending on the mechanic).

Why are you overhauling ? Any special reason ?AFAIK from your posts, even until few days back also your bike was running good.
What all will you be replacing ?
If there is no crankshaft/con rod issue then don't split the crankcases. As Sibun has also mentioned,it is almost impossible to imitate factory fitting.

EDIT: I suspect that something(maybe reagaring overhauling) is going behind secretly over Private messaging with Sibun and we are not informed about the same.
Sab ko dekh loonga !

Just wait and watch man.
I will come up with every thing. will post the pics. and the problem which i was having, and why did i opened it.
crankcase fitted. only left is clutches, block, head, magnet.

At least tell the reason for opening. I am going crazy now.

I know i have posted one query long time ago.....here http://www.xbhp.com/talkies/motorcyc...tml#post903465
that noise was not because of front sprocket, that was coming from inside. That was because of damage gear teeth and bearing.

The damage maybe because of overtightening of the old worn-out chain. I am not telling that you have done it but it could be the previous user/mechaninc who must have done that to eliminate chain noise.
I have checked that noise and it is there in atleast five bikes which I have seen(including my splendor) but it is not that loud.
Keep us updated and I am very eager to know the result.
What did sibun tell you about this noise ?

Few points from my experience -
As you have splitted the crankcases,always check with a multimter that the neutral patti is grounding correctly in neutral position. Better to replace it everytime the cases are splitted. It costs around Rs.15/- only.
Next, There is an index mark on the kick spring lock and a mark on the kick shaft which needs to be aligned.Otherwise it will cause erractic engagement of kick.
If you are re-using the cluctch plates then make sure they go back in the same order. You did not post the pictures of the re-condioned hub aluminum section,please post that also
Check for the washers under both the intake and exhaust valve springs as mentioned eariler if you are disassembling the head.
Clean the small orfice of the main oil galley to the head using a safety pin.
Lubricate everything with a mixture of engine oil and 25% grease or gear and engine oil mixture in 50-50 ratio.

Ok mate , i have a query here now , my head gasket used to leak , i mean there is dirt and grime near it..also as it is almost 45k do i need to change clutch plates ? also is oe fork oil good enough ? Or do i need to change springs too ?? How to know steering cone and ball are bad ??

Off late,our passion is having some weird transmission related issue.
Today night I was riding it and after a halt I put the 1st gear (from neutral position) and it had hardly moved 3 feet when it gave a sudden jolt and I hear some grinding noise.(Like it was half-way between neutral and 1st gear)
Due to my sharp instinct I de-clutched it without stalling and then release the clutch slowly(without touching the gear lever) and then I move hardly 10 meters when it gives another sudden jolt and I find it to be in 2nd.(It jumped a gear all by itself !)


Another incident which happened few weeks ago also :-
Few weeks ago I was in a town near factory with a pillion at a signal in neutral.(Engine was hot and time was around 1pm)
As soon as the signal turned green I try to put it in 1st but it refuses and I hear a grinding noise. I de-clutch it and then after two three attempts I finally managed to put it in gear.
After coming back I find the oil to be pitch dark so I replace it with Motul 3000 20W40.
Btw, I got back only 600ml of old oil.


God Only knows how others ride this bike !
This bike is mostly used at our factory(100 kms away from my home) and is abused by many,sometimes the oil is not changed for thousands of kilometers together and I only have to bring it back to my home(Hyderabad ) to service it. Even after repeated shoutings and warnings nobody bothers to change the oil or service it timely until it gives any problem. They just fill it and forget it.
Few months back I had spent almost Rs.15,000 on it .


Now can anyone tell me pointers for where I should start and what could be the probable problem ?
We will be selling it anyway to the supervisor For a small sum of Rs.15,000/- on EMI's as he seems to be interested in it. As a goodwill I will try to repair it(if I find time) before selling him as he works really hard at our factory. If I sell it outside,it will easily fetch me more than 22k.


Few points to note : I was also complained of difficulty in shifting and grinding noise earlier (almost 20,000 kms back)but it was only once according to them .When I checked it then,it ran perfectly.
Now it seems to re-occur more frequently.
Today I checked everything including the clutch plates,free play ,chain and sprockets and they look fine.
I have to check the clutch cable and other things as I was dark and I have found the clutch cable to be routed in-correctly.
Can only say if it has anything to do with the erratic engagement of gears only after a thorough check up of other things in the morning tomorrow.

Just today got my bike serviced and corrected the same silencer problem which you have costed total 600 rs at local mech shop, with rs.200 for silencer welding / mouth changing job, even I thought to give to local welding shop to weld it but could not find any good welder, here in chennai all are out for fleecing and dont know job, welder tells to remove the silencer and bring it to him, while mechanic tells that the mouth of silencer needs to be changed (which i think may be the head gasket, even I am not sure,), even i knew its 50 rs job but had to pay the mech 200 rs for silencer job since he is mediator and removed silencer and got it welded and fixed, but in my case the mechanic tells he got the mouth changed but for me it all looks the same.. another thing which i observed is while driving , some nutheads do drive really fast and when you apply brakes they are not able to cope up and end up dashing against rear tyre / silencer, this dash up against silencer might also create cracks near mouth of silencer, and slowly give in to the weird phut phut noise. Mechs are total rip off and very hard to find a good one. Since they remove silencer and get it welded and fix it back charge more than 3 times the actual welding cost,