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

I and Rohit have been communicating(over PM) and I did suggest him to go the DIY way but he does not have tools.
I would suggest Rohit to start DIY with the brakes then the fork and finally the head.(Even though head work requires very few tools, timing needs must be set properly and valves need to be polished ).
[MENTION=57344]RohIIT[/MENTION]

Nothing gives satisfaction like a properly worked-out DIY. Rest assured, we are here to help and guide you even if you strip down the bike completely(including the engine !).

Splendor is a very tough bike and you can hardly do anything to damage it. How do you think that most of the idiot mechanics are able to survive even after messing with splendors ?

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

A little OT, if I am allowed, please.
Rohit, we will all urge you (and torment) you to go for DIYs. That is what this forum is all about - doing mistakes, learning, sharing and helping others. I'll tell you my experience with my bike and some local mechanic. The other day I accompanied my friend who owns a Pulsar 200 (not NS) to have his clutch plates changed along with some small jobs. Because it was between the office break, I could not engage myself more actively. The mechanic on seeing my bike asked me if I had ever ridden my Hunk at all! LOL!

When I told him that it has done JSR-Kolkata-JSR numerous times and Kol-Dhanbad-Kol once, amongst some more more trips, his jaws dropped. And I proudly told him that I don't allow any mechanic to touch my bike ever. At the service center, during free services, I get only minor works done - that's IT! Nothing more. From a person with zero technical knowledge to have gained little, I owe everything to this forum and some wonderful guys (you'll find mostly on 3 threads -xtreme/hunk and splendor and karizma) without whom I wouldn't have learnt little. Also, when I was giving some insight into how the motorcycle engine works (the clutch side of the crankcase was open) to my friend, the mechanic was all ears and commented funnily that "Bangali dada log ka habit hota hai sab jaanne ka.....fulltoo technical knowledge hota hai and bahut argumentative hota hai"!!! hahahah

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

Exactly just change oil and it keeps running forever. I want to thank all you guys here for supporting me to do DIY , i too love diy but i am scared to screw up already running bike so i just do very basic diys which dont require much tools . i was reading pg135 here that how Pinaki da cleaned his brakes . I tried this on rear wheel first (with help of a mechanic) and bad news came again . The rear brake drum is gone i can say this as pads were fitted 200km before only and it has lost all its bite and braking force , Front brake however didnt needed cleaning as has ample stopping force. Can anyone give approximate cost of rear brake drum , mine is 110mm one. Also one thing i learnt hard way is to use TAPARIA tools only , a chain guard bolt got completely rounded off due to bad tools ( pliers , 11no spanner) . Had to do lot to get that out . I first see DIY here and check for tools used and spares consumed only then i proceed with it . As paul said not to hurry and go guns therefore i am proceeding with one job at a time and learning a lot in that process. I figured out that battery terminal going kaput , so soldered it and filled the cavity with grease . Now atleast battery works. Thanks to this thread and people out here that helped me to muster up guts and do things . I will put short DIY on fixing battery tomorrow ( apologies if someone did it earlier ,just sharing what i learnt )

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

Your rear drum will cost Rs.830 + 100~150 fitting charge + new brake shoes.
I don't think your drum would be bad more than mine. Mine drum condition is very much bad but still its running and have a very good bite. Brake shoes also last very long enough. Just do one thing, open your wheel, clean your drum using sand paper, if your adjustment nut is about in the end then open the brake arm (check attachment) and step it up by 1 teeth and fit back. Now you will have enough juice left in your adjustment nut.
Now before tightening the axle nut don't forget to apply brakes. Rotate the wheel, told someone to hit the brake and keep pressing then tighten the nut. If you are alone, hit the brake with your right leg, lean and tighten the nut. Or else rotate the wheel push the brake arm, that will apply the brakes then tight the nut.
Next time go for MAKINO brake shoes they come oversize and good for you. I'm using it. Cost 80.

Yes TAPARIA is good and there are also other companies who makes good tools. I have some of tools made by GEDORE and JHALANI. Honiton is also good. STANLEY is also one of the best tools making company.
You can judge the tool quality with your eyes. If you use ring or socket wrenches then nut/bolts wont get damage unless they have excess tolerance. If tolerance is less then bolts won't get damage. Usually these get damage by using open-end wrench. Therefore i avoid using these and i use ring and love using socket wrenches. They fit good and won't damage the head.

Note: You will also find CHROME-VANADIUM and DROP FORGED written on the tools. That is not a brand name.

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

Mate IMO you have used wrong spanner(11) for chain guard bolt. You supposed to use 10.

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

Yes i did this , this is called brake centering na ?? . I opened once again the rear wheel , this time on my own just to clean in a better way

How is the condition of the pads according to you ppl ? sorry couldnt take much pics as hand were all dirty and no one was around to take pics
This is the condition of brake drum

I tried removing the brake cam part . It just didnt came out so left it as it is . I would like to thank Pinaki da, shoeb , paul ,bloggingwheels and everybody that encouraged me to diy , i really enjoyed doing it even though i was drenched in sweat . As we have it , a part of something cut my finger .

No worries i got tetanus shot a month before
In this process there was bit of asbestos dust which was flying around and i might have inhaled it , i am not gonna die of cancer na ?
Man the brake bite now puts my xtreme`s braking to shame , Its so sharp now way better than before
I used detergent and water to clean some parts of brake assembly ( bolts, nuts ,springs ). lubed them with AP grease.
Love this DIY stuff.

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Yes learnt that afterwards , silly me using wrong tools and destroying bolt heads

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

[MENTION=7005]Rohit[/MENTION]- Brake centering matters a lot, without it the whole of shoe will not rub against the drum and thus braking efficiency will decrease. From the photos that you have posted it doesn't looks like drum is worn. Advancing the brake cam a bit is enough. My Joy at 3.3 lacs km is still on its original drums only the front requiring replacement mostly because it is 110 mm and with a kerb weight of 118 kg it becomes difficult for 110 mm drum brake to stop it. Splendor being lighter at 107 kg has 130mm front drum, i do not know what Hero was thinking, when it was new it was enough, now it is not enough as the drum has slightly worn(at 3.3 lacs what will you expect) so braking efficiency has decreased. If it were 130 mm then it would have been sufficient. May be i will take some day leave and change it.But my rear brake is very sharp and will easily put my extreme rear brakes to shame. Also for your problem do the following:-1. Clean the head, valves and polish the valves,2. Clean the carburettor properly and re-tune,3.Change air filter 4. Use MICO U4A plug.5. Also change the plug cap.6. For tyres i will suggest go for Dunlop Mystery or even better go for CEAT zapper that comes in new splendor pro. On my fathers bike i have seen it is softer compound and grips a lot.@all- I have not visited this thread for many days but do not think that i left this thread, i was keeping a watch on everything. Finally after 95k the chain kit is making some noise or vibration. Still there is no up-down in chain movement. I will reverse the front sprocket and then will see otherwise change to DID kit. Also i am having a bottle of VEEDOL SUPER SWIFT which i will change in my JOY this sunday. This is the best oil that i have used in my JOY. It has been three years i haven't used it in my JOY, i will change and see how the old guy feels on its favorite diet.

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

@RohIIT
How did you manage get a cut ? There is nothing sharp AFAIK.

To remove the cam you need to remove 1. The bolt holding the arm 2. Brake shoes.

Usually when the drum is cleaned using a sandpaper, a thin layer of friction material which is deposited over the time is lost and as a result braking feels poor for sometime.
Once a new layer is deposited, it is easy to lock the wheel.
@sibun
I don't know about CEAT Zapper but Secura( I don't remember the exact model but I think it was Secura M86) had a very soft compound and 75% of the tread was over with-in 8,000kms. Overall a good tyre for well laid roads but certainly not for bad roads.Got punctured more than 5 times so replaced it with MRF Nylogrip 3.0-18. More than 5,000kms and it still looks brand new with not even a single puncture.

One of my friend uses dunlop in his cbz extreme and is serving him very well. My next tire will be a dunlop as I have heard good reviews even from you.

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[MENTION=57344]RohIIT[/MENTION]
If you have removed the wheel from the bike then check the damper rubber.(Towards the chain,other side of the the brake panel)
Inspect the wheel bearing and sprocket carrier bearing and lubricate if you want.
Always lubricate the axle with grease or 90 gear oil before installing it back.

After all the work sibun has mentioned, you splendor will run like new.

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

Great job ... don't worry you'll get better and better at it . Since we have only two wheels , it is important to keep all the wheel parts in good shape .
Did you undo the brake arm on the other side of the plate as I have shown ? Then it should just slip out freely . IF it's stuck or jammed ( as in your case ) it has no lubrication inside or rusted or some other problem . Be sure not to omit it next time , if you get stuck , come here and ask . Cleaning that cam and a tiny drop of grease in it's middle makes the brake operation wonderful .

Thats good . Also once you get a cut like that , immediately wash the wound clean with soap and water rubbing the wound hard ( ignore pain ) . Then apply 2% mercurochome if you can or leave it like that . A quickly cleaned wound doesn't need any antiseptic .

As far as I can see you have the OE non-asbestos type brake shoes on .

Good , well done post the "after the work" pics if you have some .

Don't worry , I too have destroyed those exact same bolts by using the #11 side of a wrench on it by mistake . Actually you won't need a #11 on any bolt on this bike . That's why the wrench provided in the OE toolbag is a 10/12 . Unlike the number 10/11 commonly available in the market . You'll not find the OE number 10/12 wrench that comes with your bike in the market so be careful not to lose it .

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

Finished this job , I am running on NGK CR6HSA , as i was not able to find Mico plug.
Did this , but it just wont come off , so left it as it is . Next time i will use bit of WD on it to get that out . Something cut me i dont know what and it started to bleed afterwards .

Yeah those V shaped rubber grommet things they were 4 pair if i am right , Checked those too , no sign of crack or wear .I had to sand axle rod and apply grease , earlier it was very dry and came out after effort.
Yes i have trust he has given me right set of work to do.

Yes it is likely , also amount of grime was horrendous , so had to clear out that first

Oh lord you have saved my life i thought i was gonna die of cancer

Did this too , i feared that asbestos might get into bloodstream . I keep band aid in tool kit itself for all such occasions.

Weirdly i used 14mm and a 16mm ring spanner to open rear wheel , mine in 2002 model so might be change in dimensions too .
This isnt a thread anymore it has become a service manual for splendor now , we have everything from carbs to full engine overhauls explained in layman`s terms.. Thanks to all of you contributing and helping people like me

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

Mine takes 14mm and 17mm.
Glad that you loved DIY.
Now you are also initiated to this world of DIY.

OT:
Did you get the PM regd Reverse gear issue ?

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

Today i went for a small trip just 80km and i enjoyed a lot driving my bike today. It was running crazily. The road was awesome, weather was cool and little bit rain too and that was just amazing.
While coming back, it was 9 pm in the clock. There was hardly 1~2 bikes and cars passing every few minutes. And it was pitch dark all around and i love very much to drive in a dark alone. Sometimes no light was there only i can the road where my bike was throwing a light. For a sec when i turned off the light it was total black in the front. Like u are blinded. And weather was so so cold, oh god what a amazing experience i ever wanted to have. In a scary night!

The best thing i like about my bike is my head light. The light is so bright that it easily blinded the on coming traffic. I found no difficulty in driving like other guys found. When i was going in a high beam then oncoming traffic (trucks & cars) were asking for dipper. But when someone come from the front i hit low beam from far enough so that they can see easily. But some upcoming damn drivers doesn't gives you dipper, in that case i also give them high beam, and then they automatically put their head light to low and that was amazing.
Once in a way i found one extreme wala, and when we both were at same speed@60 kph, i noticed my headlight to be more brighter than him. Even one of my friend have pulser 135 and i compared my light with him in a wall, and my light was clearly noticeable to be brighter than him. My friend got amazed to see that how its possible!!

This Osram Silverstar is a amazing bulb and after installing AC Regulator of bullet machismo the light is just got superb!
But i'm gonna miss this all because next month on 17th i'm going to Mumbai to start my new career to look for a job & further study.
I wanted to have last trip on my bike so i think this is the last. I'm gonna miss my bike there a lot.
My bro is gonna benefited for all what i've done to this bike. Its almost new now.

Don't know why from few days my bike is needing choke. I've done nothing to my bike, previously it was starting in a one kick. Sometimes it also start now slowly after few kicks but need just need one kick after choke ON and when choke is off the bike didn't stall and throttle response is good. Looks like mixture is slightly lean and i got 55 kpl on highway today haha!
Thats what full throttle gives!!

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

hey buddy where had you gone yesterday for long drive. you should tell me , because from a long time i haven't gone for a long drive on my rx, so i missed the chance but as you were telling about your headlight please give me some advice for my headlight because its too low. and next month you are going Mumbai for job ???? by the way best of luck for your future .

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

[MENTION=29030]Pinaki[/MENTION]ji,
The crash guard for Xpro and Ignitor is not coming with the bike in TN also. We have to purchase it as Mandatory Extra fitting.
It is almost two months after your friend purchased Xpro. Can you ride this bike and update your opinion about driveability, FE and reliability to help other potential buyers.
My friend is one of them.

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

The fuel efficiency he claims in between 55kmpl to 65kmpl , i.e just about a little less than my Splendor+ . For other things I've to catch up with the guy and borrow a ride .