Yeah i've said before again i'm saying, it wasn't be possible anything here without Sibun. He is the jaan of this thread. If he is here therefore we and many people are here, if he wasn't here then don't know where we would have been then.

This is what coming true! Slowing i'm getting expert, but no matter how much i get, i will not be able to stand in same position as (with) you Sibun.

Thanks for the nice comment.
for your answer ques:
1) I first used kero, then carb cleaner only to cut the carbon. Then i used warm water and washed with RIN and its become brand like new. I too amazed!
2) I installed the gear dog and i installed correctly, only there was a mistake in installing clip lock.
3) Only thing was given how to install rings, but didn't given how to organize (place) them.
4) Yes i followed his method of idling & cooling because we are his followers.

Do you have any pictures of that clip installed wrongly ? Was this the clip of main-shaft dog or counter-shaft dog ?

And one more thing, I am shocked to see that the gears are damaged within 80k kms. Till date I have never seen them go kaput before 1,50,000kms.
Sibun's gear set only shows the quality of gears, maintenance and also his riding skills.

Is it due to the abuse by the previous user ie. your brother ? Clutch bell was also telling the same tale.

Anyway,congrats on your re-build motor ! Enjoy.

Check the photo, that lock is now installed in a correct way (ie, from left side), previously it was installed from right side, from the side of neutral plate.

My ownership experience!
Yes actually was bike was abused very badly, even i abused, not because i was aware of it just because i was numb.
My elder bro drove this bike from 0-to-40k on odo. He was very careless and u know that at 40k what will be the condition of the bike. I was smoking actually.
I was new to bike when i got, studying in 11 or 12 may be when i got, and at that time my age would be 19~20.
So i was new and didn't knew anything even i didn't knew which is carburettor or air filter. The condition of the bike was very bad and didn't serviced at all. I was getting very low mileage, and when i asked one of my friend he told me to get the carb & air filter clean.
I didn't knew which i carb and all, so one day i told my dad, and i took my bike to one mechanic he suggest.
I told that mechanic about the problem, and i told to clean air filter, then when he take out the air filter then i understood oh this is airfilter!. He cleaned it with petrol and it was so so dirty that i think it haven't been washed from 10k kms. It was clogged almost, after cleaning & servicing my bike was feeling better.

Yet it was smoking and i didn't knew about that. nor my dad was caring. I was using castrol, and every time i was draining it was getting low, low & low in quantity everytime.
Still i didn't know why this was happening, there was no compression, no pickup, and i continued to drive in that condition. Many times there was no oil at all, and it was ripped all the time in that condition without oil. My younger bro was driving too. The was getting super ultimate hot because it was also leaned by road side mechanic to give better mileage to his customer.

Later i was just adding oil without draining it. Because there was no oil left to drain. So i was just keep on adding more and more later when the condition become more worse. I was not having enough money to buy good quality oil every time, so i started buying the most cheapest oil available in the market.

This was a small little story, later the things which happened with me in 4~5 years i can't explain. That was a worst moment of my life. I was so frustrated with my bike that it had almost became scrap and i was getting 15000 rs for to sell this bike, but couldn't sell it because of week financial position for getting even another second hand bike. We decided to sell 2~3 times but couldn't.

After 5~7k of re-boring my crank too gone very early, then again bike started smoking badly. The condition of block again become more worse. The head packing leaked and oil started coming out of head packing (like oil ka phuara) then i used m-seal to seal that area and that didn't work. And the condition of my bike was so worst that i can't explain you. The crank was noisy that i've to drive that way for 2 years (2009 & 10), my friends started bad commenting me about my bike and said why don't u get that repaired. But what would i tell them at what position we were are at that time!!
I was like crying inside my heart sitting alone in my room, i stopped going anywhere just because of my bike. I was like suicide condition for me because of ultimate bad condition of my bike.
Now I didn't recall those days but if i get recall then i too cry today & even now!!
You don't know the past about my bike just because i haven't shared with you guys.

So u can know how badly its run, there are lot more things happened in my life which i cannot write, this is nothing.
In 2011 it was get repaired. Crank on lathe & new OE block kit and all other desi parts (cam chain, roller, clutch plates, packing & all)

So its not about the quality its because the way its handled. Even before joining xbhp the condition of my bike was bad compared to now but it was very good compared to its previous condition.
But now its become excellent because of you guys effort and my effort on DIY. Now i'll never sell this bike, now after 6~7 years it had stopped smoking and returned to its factory condition , now not even a single screw is left damaged. Even slightly damage tip were changed to OE.
After coming to xbhp i've spent more than 10,000 rs till now. Previously i was running for desi parts, but now i ran for quality parts

Even after joining xbhp i didn't knew what are tappets and how to adjust them. last year on July my dad given me my bike owners manual, and i shocked to see, because i were in thought it may be thrown out in waste. It bring smile on my face, and for the first time i come to know what are tappets and how to adjust them, oiling the air filter, clearance on things such as break-clutch lever, chain slack and all...!!

Before joining xbhp i was having nothing, but the effect of xbhp bought me these all


hehehe...

Now, Don't know if i'm lucky to get this bike, or my bike was lucky to get me.
The owner of this bike is still my elder bro. Now i'm planning to transfer this bike to my fathers name.

Oh ! This is part called as the shifter drum fork.
You made me totally confused all this while by telling that me that you installed the clip of the dog in reverse.(which is not possible)

A very heart touching ownership experience.
I think most of us might have had some kind of financial difficulty at-least during some phase of life when we did not have any source of income and depended on parents for money.
And I must say that saving and spending money on quality parts one time and have a trouble free ride is much much better than spending some money on desi/local parts frequently yet still not have peace.
Similarly,My cousin also did not listen to me and he got so fed up with his 4S champion that he scrapped the bike in middle of its restoration.He had used all kinds of desi parts and spent a lot of money already to an extent that he did not have any money left for OE parts nor did he have faith in his bike that it would perform good after full restoration.

^^Totally agree with you - sibun told me 100 times to get the USHA kit only for my bore change - i tried very hard to get one - ran around a lot but no one had it - the SC guys refused to even open the packing to confirm the make of the bore kit - and as luck would have it i ended up with the crap SAL bore again - i am cursing myself for getting the same CRAP bore again but i had no choice - just waiting for it to blow in my face again - i am sure it will in another 15k-20k kms - already done close to 12000kms :P .

I can only say that my Splendor+ is at 13600kms and less than 3 years of it's life , and down the line when it's gonna need an engine overhaul I want all of you guys to be around to help this old duffer out with that , and step by step too . Just promise me that . Whew !

My dad had bought me a hero honda cd dawn when i was in 12th... Have crossed 50k kms in the past 5yrs... Very faithful bike... The mileage is superb.. No bike can beat hero hondas mileage... Once i was riding to alibaug with my frnds. I had filled 2 ltrs of petrol.. I ripped my bike above 80km/hr all the way from the highway ... And guess what . I returned from alibaug with that 2 ltrs of petrol i had filled while going to alibaug :-)
I will miss my cd dawn as i bought a cbz xtreme :-D

SAL has too much ring gap. It is better if u re-bore it for stronger compression. Get a feeler gauge before u give it to hone. Get 1st oversize piston-rings, check the gap, if there is no gap give it to hone. And sit there to check until its done to 0.1mm gap. Thats all what u can do if u want. Get Mahale or Goetze piston, both are good.

I will only promise you if you don't tell yourself a duffer. please!
This is not a big thing and i know u will do a lot better than anyone.

Seeing your post after very long time.Is everything ok ?
Please don't call yourself-duffer but Yes,we are all duffers when compared to Sibun.
Don't worry,it is just 13,600 kms and not 1,36,000 kms. Hero engines are known to last more than that and you know this better than me.

Near 15,000 kms do a full decarb as your running is very less and that too low speed running. It will run like new,my splendor also has similar usage(although I make it a point to rip it once in a while for an italian tune-up).

You could have transferred the money and asked him to courier the kit. Or even I could have couriered it. There are many USHA automotive showrooms here in Hyderabad. I even had a chat with the sales representative of USHA and asked them to take necessary steps to get hold of counterfeit manufactures and retailers.I got a very good reply.

Yeah , but not getting opportunity to either login here or ride my bike much either for work pressures .
The new govt here is so short of money that the cops have gone really crazy fining bikers and goods-vehicles at any pretext . They are stopping bikers to do faltu papers check and wasting precious time and harassing to impose fine on false pretext when they find all your's papers are ok . Even I got stickered for 100Rs for parking inside a bylane in 10 mins .. so there's almost no parking space inside the city during daytime and can't take bike for work inside city limits during day anymore . Only running errands locally or for emergencies and rides out of the city to saltlake or rajarhat township or my hometown down south ... for all else I'm using boring metro rail . So kms are creeping on my odo nowdays and plans for another bigger capacity bike is postponed .
Also front shocks needs it's first oil change now .

I too want to complain about one retailer who showed me fake usha. How i can i do that?? Did u report that in customer care number? What they told you? What is that good reply?

So sad pinaki jee. Its very difficult to leave your bike at home and traveling in a public transport, at least for me.
I too want to re-condition my front shocks coz its very hard. You do it first, i will follow you

Suddenly the thread had come alive with Paul's detailed posts with excellent Pictures, and valuable contribution from Sibun ji and others....I have spent a very useful time with the PC learning so much now from members here....
A special thanks to Paul for the Pictures and detailed post...

Pinaki ji you are head and shoulders above most of us....so if you do an engine job,and post it here, it will be a lesson for us.

I got some parts catalog of hero's range(pdf) which includes latest bikes(XPRO,IGNITOR,FI,ZMR,CBZ...............),will be uploading it here soon !

@all- you have bestowed too much praise on me which i think is too much as i am not so much worthy of. I just helped a friend and thats all that matters. And i would like to add that i am no expert as you all have mentioned. I am still learning and i am posting what i am learning. So nothing to make me sit so high and calling yourself duffers.
Also i am glad that i could help paul in what way i can help him.

@shoeb- Well regarding your passion then let me add that since you are selling the bike then re-built the engine in max 3.5k and sell it. It will easily last for 50k or more.
Here are the list of work, you must do:-
1. Change the entire gear box from the old spare engine. Believe me it is sensible and gears are very costly.
2. Re-bore the engine with USHA piston- Cost- Rs.900
3. Change the connecting rod - cost- Rs.600
4. rebuilt the clutch housing in lathe and change GPT and change clutch plates to makino- Rs. 400
5. Use ROLON timing chain and change the two rollers- Rs. 220
6. Change push rod rubber and springs- cost- Rs.25
7.OE packing kit.
8. OE o-ring kit.
9. HERO oil- since you will drain it at 500km after first engine built.
You can re-build the engine in max 3.5k and the engine will be as good as new.

@sarbonoxely- nothing to worry, your this bore will easily run for 40k before needing attention. I will send you the USHA bore kit if you want next time and you can transfer the money after you receive the goods. Nothing to worry about. Our extreme is one of the toughest bikes around and will run a lot.

I checked the gears from old engine and upon careful inspection I can see that there are some marks on the counter shaft 11 teeth.Let me post pictures. It is already running on usha 0.25 piston and I am damn sure that the bore is glazed as all boring guys here bore out with very less clearance.I think just new rings and honing will do it but can say only after opening it.

Where shall I upload the catalogs ? mediafire okay with you guys ? Its almost 100mb and will take some time to upload. Good to see that hero has taken care of everything in it.
Don't ask me how did i got it. It even includes price list,special tools part nos,owners,workshop manual part no,accessory parts list etc.