Dealers are finding all possible ways to make money,excitement of owning a new bike makes the buyer neglect small things like these.
Recently when I went along with my relative to take the delivery of activa, the dealer demanded Rs.200 to fix the registration plates,charged Rs.50 for Temporary reg. yellow sticker(Blank),5000 for accessories,2000 to get T/R and PR by an agent. Ridiculous ! We opted to get it from outside.

Pinaki jee,If I find someone to hold the camera then I will surely post a detailed DIY. How do you take snaps with greasy hands ? I have a professional tri-pod .

So you gave him your helmet only for photo-shoot ? Just kidding.

EDIT : How much did it cost on road ? Please share the detailed break-up of cost including reg,tax,insurance etc.

Yah , actually I was busy doing the paperwork , while the friend was gleefully going over the bike . How does one suspect anything amiss anyway , when the dealer is confidently saying "iss model ke sath 5-year warranty free diya hain , issliye guards nahi atta" .
I mostly use my Iphone to take pics , sometimes I put the small nikon I have on tripods . Both have permanent drops of paint and many other blemishes now . Could never get anyone to help .
Nah , I was waiting to get rid of it , never wear the full helmet anyway , it's too hot & humid in here for that . My very old open-face yamaha helmet is the one you see me wearing in my pic here , it's my darling (it's also L size). Came free with RX . Ok , I'll get you the exact costs . Approx was near 60k .

No i used the old one. That dust seal cost 340 for two.

@Pinaki ji
Changing oil for front suspension is easier than changing brake shoes All u need is that oil lock holder, 6 mm Hex key and few tools that u have already.While popping out the old oil seal, u need to care u don't damage the seat. And use old oil seal to insert new oil-seal. Apply fork oil on its seat before u insert, that will prevent it from damage due to dry seating because they are very tight. After it seated fit the lock. While fitting oil seal u need to see one more thing, there will be SFN and one number will be written on a oil-seal that will be on the up side and not down side. And after fitting all, pour exactly 160 ml of oil, insert spring, and pump it 10~15 times. Then pull the shock up and fit rest of the things.

If i open again before u make, then i will either take the pics or record the video.

Hex key I have full metric set , what is the lock holder ? Do I need new oil seals and circlips , or can reuse the current ones as well ? they are perfect yet . You can try get a piece of suitable diameter PVC pipe to drive in that seal safely .

Pinaki ji,you will be doing this by yourself,no ? I am sure it will be a fun filled experience. All it takes is a free weekend or a Sunday and a special tool which you can make it/borrow.
As far as the cone is concerned then it can be done by home-made makeshift tools.

Even replacing the cone-set is very easy.

Hopefully there won't be any any DIY which is not covered/explained in this thread.

All thanks to Sibun,Pinaki,PSR and Paul.

Replies in bold.

The lock holder, the rod which i've made using grinding. If u have parts catalog u can check on that. There is a piston where piston ring is fitted. And to open a bottom bolt (Edit: You can see this bolt with copper washer on my very first pic of scratch pipe). We need to hold that piston. For that it is used. If u don't hold it. U can't open the bolt. And the pipe will not came out. If u have unicorn service manual, you can also check on that to how to overhaul.
U need new oil-seal and top nut o-ring and nothing else. Don't use the old one, oil can leak soon. There is one copper washer on a bottom bolt. That washer can be re-used if not compressed/damage. If u can get new then get one that too. They are cheap i've already include the price of all items.


Believe me its very easy. I too have done this first time without any problem. And i believe u can do far better than us.

Honda charges for side stand,number plates and crash guard(for motorcycles), and the so called 'accesories' as mentioned by the dealers are a big joke and rip off!! If you look at the HMSI website, i have noticed that they have separate 'Accessories' category under each bike and the number plate FR/RR costs Rs25/35 ONLY. And 2000 for TR/PR WTF, When i picked up a quote for unicorn recently they told me it was 100 for TR and 600 for PR (but if i get it done myself it will be 400).
You should be emailing the quote with those astronomical numbers to hmsi (not that the dealer is going to 'change' his ways anyway)
Only Yamaha clearly mentions on its website as to what are the 'Accessories' that should be given with the bike (included in the bike cost and not as 'extra' accessories)

Re: Hero Moto Splendor/Joy/CD-Dawn/Passion

I had conversation with Sibun on two problems. So i'm just posting it here, so that other can know about this and may benefit them.
This is based on ma low mileage problem.-
-------------------------------------------------------------
Yaar i'm getting low mileage yaar even after tuning.

After overhaul i was getting about 63 kpl, on highway too i got 63. The color of plug was bit golden.

When i was about to complete 1000 km my mileage was dropping and was experiencing 52~55 kpl on the same tuning.

After i tuned i got now 60 kpl with pillion ride. It was bit lean coz spark plug ground electrode was color less, throttle response was not good. Insulator tip is white. And there is carbon all around its circle area. The carbon is like if i drag my finger carbon remove easily. Its soft. Whereas, oil carbon was hard before.

I've also experienced different tuning with different range of rpm's. When i try to tune at high rpm the air screw went upto 1.4 turns out. But the bike was didn't shutting down after fully opening the ideal screw. So i re-tuned it in about 3000 rpm (just my guess) and then i end up with this, and the bike didn't shuts down. I'm now at 1.1 turn out from fully closed i.e, 360 degree + very slightly (even half of 1/8 turn)
Previously it was 360 degree - half of 1/8 turn

Don't know why such carbon deposit is there in my spark plug. That's shouldn't be? hmm..??
My exhaust tip also had very bit dry carbon deposit. No wet at all.

The pickup is not also impressive if i ride alone then its fine. But if ride with pillion, i feel like its my old SAL block engine.
And i've seen almost 10~15 kpl mileage drop with pillion ride. Is this really true?

I'm sure if i ride my bike in highway at 70~80 kph on this setting, i'll surely get even less than 55 kpl. I've never experienced more mileage at 75~80kph, it really drops very dramatically. Don't know how u guys get more on highway.

I'm running at 3rd position on needle. Whereas, i've checked another old cd-dawn of same age of one of my friend and that is running on 2nd position.
and i'm sure now that 2nd position is factory fitted and he didn't experience any hiccups. Then don't know why my bike is problematic on 2nd. Whereas, it was running in 2nd throughout its life and as far as i remember my bro was didn't using choke ever. And the air screw was running between 1.5~2 turns out.

Don't know what has happened to it now. Now i'm in doubt of my carburettor.
I also want to let u one thing know that, prior to joining on xbhp i was using paper pin to poke in the holes of jets, thats every time of cleaning carb.

Please help me yaar, i really want to get rid of this low mileage problem.

Then before changing ideal jet. I also had tested my top speed, which was 80 kph.
What Sibun said is- The top is less because of rich mixture and hard compression. As my engine is not yet free therefore its top-end is less. After the my engine will cross 3000 km it will become free and top will increase.

How to know if it was due to rich mixture?
In the end my engine was going very slow from 70 to 80 kph. The rpm was increasing but speed didn't. Thats due to rich mixture.

As you guys know. When i was running SAL block and on 2nd position on carb needle my bike was taking lots of hiccups as the mixture was getting too much lean. So i was running on 3rd which was rich. To clear this doubt of my factory setting, I check the carb of one of my friend cd dawn which was of same year. And it was running on 2nd. I asked him if it runs fine without any hiccups or anything. He said yes. Also that bike was in worst condition.

So this thing made me confuse that time as i don't know why my bike didn't run on 2nd. But after overhaul i was still running on 3rd. And as my mixture was rich, and carbon depositing on plug. So i thought to now to try 2nd position again.

And after switching to 2nd position again, i replace my air filter, re-tuned the carb. and now the bike is running better without any hiccups at all. No choke required. Also there is less carbon deposit on exhaust tip. Spark plug is still to check after few hundred kms. Mileage is still to check. But overall i expect better results now.

But ideal-ling is still not good. I checked replacing the slider from my friend passion and got very bit difference. I try to find here and didn't got anywhere.


My another problem was cam chain noise.

This was the PM i send to sibun
------------------------------------------
""Hey man i wanna get rid of my cam chain noise. I have stretch the spring still there is no gain.

I have no other option left without installing again a HERO chain.

I clearly remember when i installed ROLON for first time there was no noise. But it appeared after 200-300 km of run in.

Same case happened with DIAMOND accuro too. Had ran good for the first few hundred kms.

The chains where tight still there is a noise. SO WEIRED!

I am pissed off

Don't know what to do!!

I think i need to show to any mechanic. Just to show, i will not let him touch anything.""
----------------------------------------------------------------------------------------------------------------

Sibun then asked to his mechanic about my problem. And mechanic said its may be because of lack of lubrication so to check push rod valve if its not clogged and to clean it.

Another PM
---------------
This was my tensioner which had gone crack, i installed this on last sept-12 at 89200km on my odo. And now its 94300 so almost it had ran 5000.





only cracked from outside, inside metal is fine. But it was moving freely inside.
I changed spring too that time.

I saw this crack when i installed my old HERO chain now. So diamond & Rolon was running on this.
It was my OE & 100% genuine. Still crack....strange!!

So i installed my old tensioner which is also fine, but its more free than this. Also i've put ma old spring by stretching it.


So tomorrow i will again try installing Diamond back.
Its of Aug-11 packing with MRP 110. And distributor given me for 110 saying that its price has increased.

One of my retailer told me, diamond's hard bush chain kit was having lot of problem. It was coming with warranty and company had replaced many chain kits. At last they stopped manufacturing that.

So i don't know if this ACCURO may have that kind of problem. Even he was a distributor and he had 2011 pack . Daal me kuch kala lagta h!!

So now i'm going to install back my diamond chain again. And lets see what happens.


Edit:
This push rod valve is not clogged actually.

Re: Hero Moto Splendor/Joy/CD-Dawn/Passion

As sibun mentioned,there is no substitute for experience. Many members (including me)have only theoretical knowledge and almost zero experience whereas sibun and his mechanic have real world experience. Kudos to you guys !

Many make the mistake of cleaning the jets with pins or a thin single strand wire,eventually the jets will become oversize and the mixture gets rich.

Blowing compressed air or a bristle plucked from a brush works best. Carburetor cleaner comes handy to clean the jets and passages.
If carb cleaner is not available then I fill a syringe with petrol and use it to clean the passages.

Check the Slide piston and the bore(carb body) for any scratches or wear.

Top end performance hampered means that the Needle/Main jet is faulty/over-sized due to repeated poking using metal pin,the mixture is getting excessively rich. On the other hand there will not be much difference in 1/8th of throttle as you tuned the mixture correctly. Compared to the tuning of idle jet,main jet takes a lot of experience and takes a lot of trial and errors.

Get genuine Keihin jets (both idle jet and main jet) along with needle kit and slide. This will fix the problem but if the body is damaged then the only option is to buy a new carburetor as sibun advised. Make sure you buy only genuine O.E/Keihin stuff(hard to find) and not the local stuff which you get easily.

Problem with bikes owned/used by others is that it takes a lot of time and effort to solve the problems which were caused due to the negligence of previous owner.I thank god even though my splendor was used by my father,I always accompanied him whenever he got the servicing done so I know what all was changed/service and what wasn't.

@All - (Off topic)

Few days ago I promised myself that I would never get any work done by a mechanic however small/major the job maybe. Not even a job as simple as chain adjustment. Few days back,I got the chain adjusted as my #30 spanner was in our factory so I took the bike to get it adjusted at a local mechanic. That mechanic tightened it too much and after getting home,I had to take it back to get it re-adjusted but still it was very tight. Fed-up with this,I purchased another spanner and adjusted it myself. (I now have four #30 spanners)
The problem I faced with tight chain was the the gear would suddenly jump out during sudden acceleration, had a talk with sibun and he confirmed that it is the over-tightened chain indeed.

I am so pissed with the two wheeler mechanics,only my four wheeler mechanic is good and is more of a friend than my mechanic. He always shares his tips and I share my electronic knowledge and update him about the new electronics used in new cars. Apart from mechanicals,I also get to learn some good moral values from him.

Re: Hero Moto Splendor/Joy/CD-Dawn/Passion

I was not poking crazy like what u guys are thinking. I know it can increase the size of hole, so i was just poking a bit to clear it only. Not like damaging it lol
There is no scratches or abnormal wear in the carb.
Let me post micro pics of my jets someday. That will show everything what we can't see through our normal eyes.
Let me test out the mileage first. I am also thinking to leave my carb whole night in acetone.
ANd yes i always buy genuine products. Whatever prices i've included in my post so far are OE only.

Re: Hero Moto Splendor/Joy/CD-Dawn/Passion

Dear Paul, I am not blaming you. Damage could have been done by the previous user's mechanic (your bother's mechanic).

Keep us updated on what you find.

Re: Hero Moto Splendor/Joy/CD-Dawn/Passion

I am sorry...belated Happy Birthday Sibun !

Re: Hero Moto Splendor/Joy/CD-Dawn/Passion

Belated Happy Birthday wishes Sibun...

Re: Hero Moto Splendor/Joy/CD-Dawn/Passion

Belated happy bday sibun , wish you many more happy miles and times

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Belated happy bday sibun , wish you many more happy miles and times