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**shoeb2015** · 06-25-2013, 12:04 AM

Re: Joy tank and panel part numbers

Originally posted by sibun View Post

Yes, complete catalog in hard copy as Joy catalog is not available in soft copy. I have the complete catlogue from a to z.

Is it with you right now ?
If possible Attach a copy of Fuel tank section. If scanner is not available then even a photo taken by camera will work.

EDIT : Both the pictures show side panels. (Btw,Do you always keep the catalog along with you ?

)

**Pinaki** · 06-25-2013, 12:32 AM

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

Originally posted by RohIIT View Post

... Jee , the problem with it is that it has very high play and by wriggling it the lid is opened , doesnt even need key for that . I dont have any idea how to replace this part ...

Just unscrew those two phillips screws and the door shall come off ( might need a drop of sewing machine oil on them for 15mins to loosen ) . Check where the problem is and it should be an easy repair or weld fix . nothing to do with the tank itself . Infact if black colour door was acceptable , you'll readily get that part as spare from Hero authorised parts dealer .

Originally posted by paul.1911 View Post

... Don't know why my speedo needle is wobbling at 35 kph and 80 kph. My inner cable is new and lubed. I applied white grease on small mechanical plastic gears of my meter and still it wobbles. ..

You didn't get any grease or oil onto the square-ground part of the inner cable that inserts into the meter at the top ? That part should be clean & dry . Same with the square-ground lower end of the inner cable that goes into the wheel-pinion . If it gets oil or grease somehow the cable that is inserted in there slips , this happens at certain speeds when the turning force is high enough . Also soon the square receptacle hole under the meter where it goes in gets rounded off by repeated slipping of the rotating inner cable , and eventually meter fails . I have had this problem before on a yamaha .
It seems you have eliminated all the other usual things .

**shoeb2015** · 06-25-2013, 12:51 AM

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

Originally posted by Pinaki View Post

Just unscrew those two phillips screws and the door shall come off ( might need a drop of sewing machine oil on them for 15mins to loosen ) . Check where the problem is and it should be an easy repair or weld fix . nothing to do with the tank itself . Infact if black colour door was acceptable , you'll easily get that part as spare from Hero authorised parts dealer .

I have recently replaced this lid as it was scratched badly. Got a replacement lid made by TOP, paint quality is not that good. Rs.90/-

Yes, tightening those screws should reduce the play. 17511-KCC-905ZC LID COMP, FUEL TANK (CANDY MISTRAL BLUE )(?) Rs.191/-

**paul.1911** · 06-25-2013, 02:05 AM

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

Originally posted by Pinaki View Post

You didn't get any grease or oil onto the square-ground part of the inner cable that inserts into the meter at the top ? That part should be clean & dry . Same with the square-ground lower end of the inner cable that goes into the wheel-pinion . If it gets oil or grease somehow the cable that is inserted in there slips , this happens at certain speeds when the turning force is high enough . Also soon the square receptacle hole under the meter where it goes in gets rounded off by repeated slipping of the rotating inner cable , and eventually meter fails . I have had this problem before on a yamaha .
It seems you have eliminated all the other usual things .

No I dont have this problem. Nor i have ever face this problem. My cable is quite new and i didn't lubed that square part. I checked already and theres no slippage problem. Square part is only meter side.

**sibun** · 06-25-2013, 09:59 AM

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

Originally posted by shoeb2015 View Post

Is it with you right now ?
If possible Attach a copy of Fuel tank section. If scanner is not available then even a photo taken by camera will work.

EDIT : Both the pictures show side panels. (Btw,Do you always keep the catalog along with you ?

)

Oh! i am sorry. I mistakenly posted both the side panel pictures. I tried editing and inserting that photo but it showed error. I will insert the photo here.

Yes, i have the catalogue always with me.

Originally posted by paul.1911 View Post

No I dont have this problem. Nor i have ever face this problem. My cable is quite new and i didn't lubed that square part. I checked already and theres no slippage problem. Square part is only meter side.

Get the round pinion in wheel assembly changed. it is plastic one and will have slightly worn out. Yours is old one like mine with screw type cable and the worm gear is made of metal so it doesn't wear out. Change the round pinion.

**RohIIT** · 06-25-2013, 05:11 PM

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

Is this tool ok to be used ? . The rod is 2.5-2.8ft in length and has 1ft rod in perpendicularly welded at bottom.

Just unscrew those two phillips screws and the door shall come off ( might need a drop of sewing machine oil on them for 15mins to loosen )

Unscrewed and re-screwed them back , pardon me i am using your pic for my query .

The yellow ring is the area where the play occurs , it can move forward & backwards so lid easily comes off .

Yes, tightening those screws should reduce the play. 17511-KCC-905ZC LID COMP, FUEL TANK (CANDY MISTRAL BLUE )(?) Rs.191/-

Asked to SVC about this part , they will get it within a week , Also thanks for the color , I will look out for it .

**shoeb2015** · 06-25-2013, 05:19 PM

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

Weld the center of the nut for more strength. Rod should be perfectly straight otherwise fork's inner surface could be scratched.

If that hinge has play then replacement is the only option.

**RohIIT** · 06-25-2013, 06:57 PM

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

Originally posted by shoeb2015 View Post

Weld the center of the nut for more strength. Rod should be perfectly straight otherwise fork's inner surface could be scratched.

If that hinge has play then replacement is the only option.

Yes i told welder to make a exact copy like yours and showed him pic , but he told that it might deteriorate the nut edges rendering it useless ( nut was Stainless steel )
I will get rod straightened .

I have placed order for tank lid hopefully it will arrive next week . Will that lid have sticker or i need to get that separately ? .

**paul.1911** · 06-25-2013, 07:08 PM

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

File this thing. File all over a nut so that it will fit inside the piston easily.
Use hammer and straighten the rod in a rail line. You can get that rail line for use in your nearby construction area. They all use it for lot of purposes.

**RohIIT** · 06-25-2013, 07:32 PM

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

[MENTION=6724]Paul[/MENTION] : ok i will do it , actually other side of the nut has same aberration like you showed. I am thankful that you pointed out the problem in tool otherwise i would have used it as it is . I will file it tonight or by tomorrow morning .

**RohIIT** · 06-26-2013, 04:17 PM

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

Straightened the rod and filed the nut . The person heated the rod and showed me how to straighten it .

bought a 200ml beaker from pharma store as the measuring funnel wasnt that good and he suggested beaker to be better .

Opened shocks drained oil and loosened bottom allen nut .

I was having doubt that the tool i made might vary in dimension and may slip inside piston . Exactly this happened today , just as i inserted it started rotating it a bit , it easily slipped .
I didnt have any idea what to do now , called up a local mech and he confirmed that tube it bent it lower end (not much but still it is bit bent) which is causing sluggish upward movement also oil galleries are completely clogged due to this ( When i drained oil it had black particles which were clearly visible) .

I will weld a 11mm nut and try whether it will work . Also when i loosened the lower allen bolt , it kept on rotating and piston wasnt free ( i was able to hold piston with the tool but coudnt rotate it)

**shoeb2015** · 06-26-2013, 08:09 PM

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

Originally posted by RohIIT View Post

I was having doubt that the tool i made might vary in dimension and may slip inside piston . Exactly this happened today , just as i inserted it started rotating it a bit , it easily slipped .
I didnt have any idea what to do now , called up a local mech and he confirmed that tube it bent it lower end (not much but still it is bit bent) which is causing sluggish upward movement also oil galleries are completely clogged due to this ( When i drained oil it had black particles which were clearly visible) .

I will weld a 11mm nut and try whether it will work . Also when i loosened the lower allen bolt , it kept on rotating and piston wasnt free ( i was able to hold piston with the tool but coudnt rotate it)

You are supposed to place down the T with the _ towards the ground. Invert the fork, slide the tool,make sure it has fit properly on the piston and then loosen the allen bolt with a sudden jerk.
As it has slipped, don't do anything further- just go to mechanic and borrow/use his universal fork piston holder rod.

As I mentioned previously,oil galleries have slugged-up. Piston cannot bend,pipe can.

**RohIIT** · 06-26-2013, 11:30 PM

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

[MENTION=14414]shoeb[/MENTION] Yes i tried everything but there seems to be some problem. The steel pipe is bit bent in lower part , the piston is ok . I will be going to svc tomorrow for servicing of xtreme . So will not be able to work on splendor , mechanic also tried to open with his piston remover but it was also slipping , so i need to get this done by svc , their tool is good for this. Maybe i will try to buy their tool if possible
Paul thanks buddy i am trying my best but this fork has created pain

**paul.1911** · 06-28-2013, 06:03 PM

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

I changed wheel speedo pinion then checked wobbling and it was still there very slightly. I had lubed the cable with grease so [MENTION=43108]shoeb2015[/MENTION] said to clean the cable and to lube only with oil just to check if that help. And i think it helped and i'm almost there, but once if test in 80 kph then i can say confirm.

[MENTION=28527]sibun[/MENTION]
I went to all 3 ASC in my city and they said didn't have and not they will place order. I went to Ranchi and asked in 3 ASC & 1 Distributor there and they didn't have too, but one of them agreed to place order. I called ASC in Chaibasa@64km from here and they didn't have but order can be placed there too. They will charge full amount before taking order, refundable if they can't get, but the problem is i'm leaving Jamshedpur on 17. Need to think about this.
Did you tried calling Hero toll free number 1800 266 0018 ??

**sibun** · 06-28-2013, 10:49 PM

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

Originally posted by paul.1911 View Post

I changed wheel speedo pinion then checked wobbling and it was still there very slightly. I had lubed the cable with grease so @shoeb2015 said to clean the cable and to lube only with oil just to check if that help. And i think it helped and i'm almost there, but once if test in 80 kph then i can say confirm.

@sibun
I went to all 3 ASC in my city and they said didn't have and not they will place order. I went to Ranchi and asked in 3 ASC & 1 Distributor there and they didn't have too, but one of them agreed to place order. I called ASC in Chaibasa@64km from here and they didn't have but order can be placed there too. They will charge full amount before taking order, refundable if they can't get, but the problem is i'm leaving Jamshedpur on 17. Need to think about this.
Did you tried calling Hero toll free number 1800 266 0018 ??

Man you are too aggressive in everything. I had just requested you to look at your near-by ASC and you have searched the whole of Jharkhand. If i remember correctly when i had gone to Ranchi, jamshedpur was almost 140 kms from ranchi. Man, you have gone this far for the parts. Thanks for all the trouble you have taken for me. Regarding, you leaving on 17th do not worry, best of luck for your future and regarding that parts i will definitely get it from somewhere. You go to mumbai and start a new life. Nothing to think about this. I will get it somehow. Thanks for all the trouble you have taken for me.

I will call that number do not worry.

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