your head gasket is leaking, your bike is smoking, have very less compression, hence very less pickup, does not pulls up fine, u need 2nd or may be 1st gear sometime.
Actually u need to get it re-bore to make it as a new condition.
Yes u need to change the clutch plates also. I haven't use OE fork oil, i've used veddol may years ago and fork was soft. later when i used castrol it became very hard. Here sibun & shoeb uses Motul fork oil and that is best according to them.
For springs u don't need to change it. I u can check it should not be less than 368 mm. But actually it doesn't required.
For handle racers, stand your bike on a main stand and keep your handle straight 12 o'clock, then slightly give a touch in right and it will move towards left easily to its end. And again straight your handle then give a touch in left, and it will move towards right easily to its end.
And if it doesn't move, means your racers are worn. Means when your handle is at 12 o'clock and when u push it either side, it stucked at 10 o' clock or 2 o'clock, then it means they are worn.

I'm sure your gears are excessive worn, open the chamber and i think u would need to change it as a complete set. I've replaced the 4 pinion gears and they cost 1500 now u can imagine how much whole set will cost. My gears are wasn't creating any problem but i replaced it because i don't like temporary measures.
Please open that engine i want too see their condition. how they were running.

Last time when I had opened it(75,000 kms back),the counter shaft and main shaft was worn out where the gear spins on the shaft. I did not replace it because it seemed normal that time. All the gears were fine,only the shafts were worn out a little.
But I am still waiting for Sibun's reply to proceed any further.I know that if I open it now then I will have to spend at-least 10k to get it in correct shape. IMO it will be better if I sell it "AS IS".
Lets see !

Ok , my kicker is bit easy to kick , i mean it doesnt require much effort , is that due to lack of compression ??

yes absolutely get that re-bored and your compression will be back.

@ Paul

Can you please translate the "transmission/gear box" section of the CD-100 manual into English and PM me/upload it here ?

why u need that its easy to fit. Moreover, you are also a DIY man, u have an spare engine that u have worked with.
I didn't even checked that manual and there is no chance that i'll fit in a wrong way. Only u need to make sure about the chips & washers. If u bought a set then no problem. If u only change the gears. then u would need to remove the clips which is very difficult and hand may cut. Once u remove u need to make sure about its order. which u can see on manual. Once u install it will become slightly loose, then use plier to press. It will rotate in its place, also u need to check if that clip went into the groves in the shifter.

and when u remove dog for inspection, make sure u install the clip from the IN side not from outside direction. I mistakenly installed from out, and it fall down inside the chamber when i kick to start the engine. and then i needed to split the chamber again.

No special reason Paul,just wanted to check what they have written as it is a very old manual.I was astonished to find that Hero Honda made a workshop manual in foreign language for export markets long ago and we find it difficult to find the English manuals of world's largest 2 wheeler manufacturer even now.

Thanks to Sibun,I have overhauled many two wheeler engines of my friends and they continue to run perfectly.
I wish to overhaul and restore a battered Maruti 800 of my uncle lying unused at his home someday.
Now that I don't find enough time to do all this,there are many small wishes waiting to be fulfilled some fine day.
Automobiles has been a very time consuming hobby of mine and will remain no matter what !.


Always before fitting the bore and head,temporarily install the kick lever and check if it moves freely.
Same with the gear lever,check that all the gears are engaging properly. Just turn the kick,shift the gear and repeat it so that everything is installed correctly.
Once done,shift the gear into neutral and turn the front sprocket counter shaft and see that there is no noise or binding of gears.
This will not only ensure that the gears are not binding but also will ensure that kick ratchet is not engaging in retracted position.
Installing of the kick spring lock becomes easy if you have a "opening type" snap ring pliers.

EDIT:
I forgot to mention that once the crankcase gasket(or any paper gasket) gets soaked in oil and then if it is compressed (in this case by tightening the crankcase bolts). It should not be re-used preferably because It will loose its sealing capacity.
The paper gasket forms a tight seal by expanding when coming in contact with oil thereby by filling all minute gaps.

If you have assembled the engine and used original packing kit then don't worry.
Cheap local packing kits loose their sealing capacity after getting compressed even for a short duration of time.

I used original packing kit, but later when i opened, i only replaced crankcase packing, block packing, and head oil seal. And rest are used same because they were fine.

I have driven my bike now and its running very good now.
It wasn't be possible without Sibun, so want to thank him heartily.

Only i pray to god it wouldn't smoke now. and should run for thousands & thousands of kms.

I will come up with all my experience later because currently i'm not that very well, i couldn't have food as i was taking before. There were 4-5 cuts on my hand so want get that healed before.

Today when i drove my bike, i feel sooooo happy as i was driving after a break of month but it was only 5~6 days.

Now, there are more things to done in my bike,
fork re-conditioning as they are very hard and i feel jerk a lot.
Want to either re-condition or replace rear shocker as they are also hard, and oil has leaked. (have already get re-make but didn't last even for a year)

but before that want to get change the rear brake drum (running worn from 5~6 years), brake shoes have also gone, but before i replace shoes want to get replace drum along with new shoes.
So which is best one to go for? Who is the supplier to OE??

Please don't be offended but isn't this too much ? I mean getting yourself hurt repeatedly and unable to sense pain while enjoying DIY ?
Yes,I know the excitement of DIY but it should be in such a way that you take all precautionary safety measures.
Till date I have been hurt only once while working on bikes and that was when the sharp clutch housing gear slipped because I carelessly picked it up with a thumb and middle finger.
Unexpected things can happen but it can also be avoided.

Next time,Please don't use a spanner to remove the valve springs. That is tool abuse.
Valve keepers or springs could go flying or may even hit in the face or eyes.

Please be safe and WORK SAFE ! We want to see many more DIY's from your side and not DIY injuries.

The cut mark isn't to deep, they are slightly.
One cut was happen while removing cir clip from kick shaft. I have the tool for removing clips but it was wasn't with me, it was in my old abandoned home.
Another 2-3 cut while removing clutch cover gasket on a chamber side, not in my engine, it was my friends passion was to install new clutch. The gasket was very hard.
Another 1 cut happened while removing cir clip from main shaft of mine for installing new gear pinions.

huh, mistake happens. Even experienced persons do the mistake. After all it was my first time and i realized how the work is tough.

Installing valve springs is now not tough for me, i can easily install now in a minute or two.

Speaking of clutch, i want to say, don't use gears to tighten the nut. It may hurt the gears or anything inside, even my mechanic told me it shouldn't be done like that. So better u buy clutch holder for now, i bought for 120. Don't risk your parts inside its worth a lot more than 120.

Is there any DIY left from my side? what are u expecting man from me now??

Even before, checking the gearbox, check the pressure plates and clutch center. See if the pressure plates are bent or the clutch hubs grooves are damaged. As both of these will have same problem. A faulty clutch will give the same problem as with other issues of gear. Also while opening the clutch check the gear shifter of the gear shaft. Check the spring and the shifter arm. If the shifter arm is bent then same problem.

Also you have stated counter and main shaft to be worn, that may be the problem, but first check what i have told and then proceed.

In my opinion, if you are selling it to your worker, then better to repair it and sell otherwise, he will not be able to tell but in mind he will feel bad about it. See, you have a spare engine, just transfer the gearbox from that engine to this engine. No expenses occurred. Just rebore the engine to next oversize using usha pistons. Within a total of 3k, i will be able to help you re-build the engine. If you want to know how then reply to my post here and i will tell you how.

1. Rebore the engine using USHA pistons, and compression and oil fouling problem will be solved. Do not go for new bore kit as since your bike have run 45k after some 25-30k, your con rod will show play which will accelearte the wear of new bore kit. So go for re-boring and when con rod will develop play, open complete engine to work and then new bore kit.
2. Front shock open completely and overhaul. Simple oil replacement will never work. For guidance, check my post in extreme thread where i replied to sarbonoxly. Use MOTUL oil in shock and quantity after dismantling is 160 ml in each fork. It will not be soft as extreme as splendor runs harder shocks. Even in extreme, the front shock is too soft and instead i will use MOTUL oil in shock this time at 10k which will make them slightly harder. Motul shock oil is of 20W grade.
3. Change the clutch plates, no need to ask.
4. Change the plugs and plug cap. Plug to MICO U4A and cap to OE black one.
5. check the chain sprockets and if worn then change to DIAMOND or ROLON. If not worn, open them and clean with kerosene and then fit back by lubricating with gear oil- see DIY thread of extreme chain cleaning of mine.
6. Check all electricals and also check the wheels for any bend. If bend then take it to rim shop who mens spoke wheels.
7. Check both tyres for grip and hardness.

Sibun Bhai,Clutch plates are OE and almost new,Clutch inner and outer was also replaced along with clutch plates.
Clutch housing is old and bushings have play. Shiftier rod and spring is fine.
And,What about the gear ratios ? What is the cost of completer gear assembly ? Cost of Counter Shaft,main shaft if purchased individually ?

I am also suspecting the shiftier fork's tab which pushes the dog assembly. As it wears out quickly if run with less/old oil.
If possible please send me the parts catalog.

You are right,I will get it repaired before selling it.

Probably next week I will open the engine and keep you guys updated.

Some OT , but as it is now part of my passion so posting here .

Need some help guys .
2 days before fitted CCFL Angel Eyes to my Passion , to turn the monster into angel
But as i wash my bikes everyday if possible, so i packed the inverter of CCFL Angel eyes in plastic bags making it waterproof .
Also its been around a month my bikes are at rest so battery is down , so CCFL angel eye got some fluctuating supply & no way to pass out the heat .
Resulted in burning of both 8050D Transistors from inverter Good thing is i found them in electronics shop , replaced them but it isn't working .
Angel Eyes are not turning on.
Googled for solution , but nothing found .
I got 2 rings of CCFL angel eyes with inverter for 300 rupees . Checked for replacement inverters on ebay found them mostly around 500/600 rupees .
The circuit seems to be very easy to build & cheap , but finding those components are difficults as there is nothing mentioned on coil & transformer .
The number mentioned on the inverter is rsa-1020
it is similar to this



But instead of those electrolytic capacitor there is only one coil .

other parts are

2kΩ 1% =2

27pf 3KV =2

68 nf =1

1n4007 =1

8050D =2

Any one have any idea or solution for it or other components value please share it .

My overhauling experience!!

[MENTION=14414]shoeb[/MENTION]
You might be thinking why I've overhauled my engine if it was running fine. But actually my spark plug was telling me a different story!!

@all
My bike was smoking a bit from many days. You were know before DE-carbonize, my bike was smoking badly and head packing was leaking. When I opened for the first time I found damage valve oil seals and oil was leaking because of that. After replacing oil seals the smoke was not visible at all, I thought my problem is solved.
But I was wrong.

My bike exhaust tip was still showing the signs of smoke. But there was no oil coming on spark plug threads, it was dry. But the base ring was always black no matter how many times I cleaned or tuned.
I posted my spark plug pic so many times, but no one could report to my problem except [MENTION=28527]sibun[/MENTION][/MENTION]March 02, 2013 @ 10 AM (Saturday)Click on the pictures to see the larger view!!






Before opening I went to mechanic and saw one splendors awaiting assembling, and I saw how to assemble and I found easy.

DAY 1 (Wednesday)
I made tools that I require i.e., magnet holder & puller on 6th, same day opened my engine in evening. Decided to clean every part the same night. Unfortunately, got some other working to do. Got back at 11 PM night and got the chamber split at 12:30 AM.

See the condition of combustion chamber, 2000 kms after de-card. The exhaust valve is slightly red.




It was time taking to me, after all, was doing for the first time. Keeping all things in mind. The clutch bell collar (dowel pin) was not coming out because edges on the grove of the shaft was up bent slightly therefore got stuck there. I had to file the corners to take it out. In new shaft collar easily went in.

After splitting I saw gears were damaged. Sent PM to [MENTION=28527]sibun[/MENTION], in reply got opinion to change the 1st & 2nd gears of both shafts. Thanks for the help [MENTION=28527]sibun[/MENTION]!



Working in the night shift

Day 2 (Thursday)
Make a list of parts I need, called my friend (Passion wala). He gave his bike me to drive, I will not drive I replied, haven't slept at night & feeling sleepy now. He then damn said he itself didn't slept in order to talk to her GF whole night, he too was sleeping. I was like WTF! I didn't wanted to drive still drove & went to the nearest ASC to get parts. But unfortunately out of 4 gears they having only 3, so except gears bought the other parts. Went to another ASC & there I got all 4 of them. Also bought bearings for counter & main shaft from SKF dealer.

Parts bought:-
Valve oil seal- Rs.64
Cam chain guide roller- Rs.67
Cam chain tensioner roller- Rs.48.50
Oil pump sprocket- Rs.79
Head O-ring kit- Rs.47
Gasket kit- Rs.227
Clutch lever spring- Rs.7
Neutral Patti- Rs.10.50
Clutch springs 33x4 - Rs.132
Main shaft (11t) [23211GF6000S] - Rs.386
Gear main shaft 2nd (17t) [23431GF6000S] - Rs.356
Gear countershaft LW [23421GB4770S] - Rs.432
Gear countershaft (24t) [22441GB4770S] - Rs.404
Hero engine oil 10w30 - Rs.190 (crap)
Rolon cam chain - Rs.90

SKF 6001 1nos - Rs.100
SKF 6203 2nos - Rs.200
Resibond 330 - Rs.20

I went out at 10 and came back at 3 PM, my friend bought new clutches for his passion, then at evening leaving my all work I went to fit those clutches to his bike. Started at 5 PM, damn got completed at 9 because of gasket, and was so hard to remove, although it was all stick to the chamber side rather than on cover. On 1/2 an hour job wasted my lot of time because of gasket. Once again I got exhausted and didn't left anymore energy to work on my bike that day. As of having 2 hours sleep, I didn't work at all and went to sleep after having dinner.

Day 3 (Friday)
Started washing my parts afternoon, removing gasket, cleaning, lapping valves etc. After cleaning all the parts, left to dry. On the other hand, begin to install gear pinions, found it very difficult to remove clips alone so took the help of my mummy






After all the parts got dry, started assembling all. Before I fix/bolt the chamber, thought to ensure if all the gears were shifting properly. After testing I found sometimes it shifts all four and sometime getting stuck. I didn't knew aware of this that after installing clutch assembly gears will start working perfectly. So as of unaware I thought there is some problem. I couldn't figure out as to why I am having problem, as per my knowledge I installed all the gears correctly.

Day 4 (Saturday)Parts that were bought again:-
Head O-ring - Rs.47
Crank case gasket - Rs.28.50
Cylinder/block/bore gasket - Rs.21.50
Plug rubber 19mm - Rs.8
Head dowel pin for O-ring 8*14 - Rs.5

Total cost incurred on parts- INR 4,330.


Pardon me for any error or mistake.


UPDATE
On my old crap SAL block, the ring gap on 1st compression ring was 0.5mm and on 2nd compression ring was 0.7mm. More than its service limit.

Last updated: December 07, 2013.
Correction done on spelling errors and mistakes.

Simply Excellent !
Never In my life I can thank Sibun enough for all the efforts he puts in to help us. Now this PM and your post is a Bible to anyone who is overhauling engines.
I am amazed by the time you have spent on cleaning all the parts and the engine looks brand new.
I am not telling that you have not done correct by not going to Sibun' place but In a way you have taken the right decision by doing it yourself.
Doing it yourself is the only ultimate way to bond with the bike. I am more than 100% sure that this bike will bring a new smile on your face ad you will love it more as the time passes.

Please answer these
1.How did you clean the engine ? Did you use Carburetor cleaner,Diesel/kerosene or anything else ?
2.I did not get this,How exactly did the mechanic install the gear dog in reverse ?
3.Does the Usha kit come with installation instructions.
4.Did you follow sibun's method of breaking-in the engine by idling it and cooling it for one hour ?

Once again, Excellent job Paul. We have the most prized possession here- SIBUN.