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

The problem was with spark plug cap.The part where it attach to the wire (the screw type thing) was in greenish blue in color and plug caps terminal connecting part was corroded fully.Changed the spark plug cap and the problem solved and now idle is steady in normal and left tilted position

I use this shell ax7 in my yamaha gladiator and fazer ( old ) . I felt noticeable difference while using this oil such a smooth and feather like gear shift,free revving,engine vibration reduced considerably, feeling the same in splendor . will this oil give same protection as 20w 40.Is that like a thinner oil gives higher rpm

a small repair and a modification

This rubber ring had come loose and kept falling out of it's fixture .



So I affixed it on this time with some superglue , hopefully this shall hold for good .




Next I did a small mod to the front mudguard . The OE mudguard still picks up some mud past it's lower part and throws that into the horizontal slung motor . So during monsoons , many people inculding me have to resort to this rubber mat kinda flap slung on to the crashguard bolts . It is quite effective in keeping the engine bay clean but it cuts out the much needed airflow to this hot motor and looks ugly . ( mudguard removed for the work ) .



So I added a mudflap extension to the mudguard itself and removed the ugly mat . And yeah , I know it is not a perfect fit , but it does the job really well and has not struck ground at any of the local backbreakers , so I really don't mind the non-hero looks .




The part is OE from Bajaj , probably intended for the P135 or discover models .



Additionally you'll need 3x No 8 nuts , washers & bolts to affix it . Available at any bike parts shop .



Firstly I took off the front mudguard by removing the four No 10 nuts that holds it to the fork legs and cleaned it up a bit .



Then I taped the 3 approximate puncture areas with yellow electrical tape .



Then made more accurate marks with sharpie by placing the extn piece on and marking through the holes .



Then simply drilled the 3 holes with 4mm bit on an electric drill . A hand-drill would be nicer and more accurate for such small job .



Then I smoothened out the hole's edges with a rat-tail file .



So that a No 8 bolt would just slip in snug .



Baas , now you can just bolt on the extension mud flap and tighten the bolts with two No8 wrenches , one for holding the other side .



Additionally , I coated each bolt on both sides with clear synthetic wood varnish and let it harden overnight . This shall prevent bolt slip from vibrations and rust too (hopefully) .



As I said , it isn't a perfect fit since the mud-flap extension is designed for the more squarish bajaj mudguards .



But it works just fine and looks better IMHO than the ubiquitious dangling rubber mat type flaps . So I posted this if anyone may find it of use .



Comments are welcome .

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

[MENTION=29030]Pinaki[/MENTION] ji
well done. But why you didn't used flapper of old cd-dawn. It is availabe at any spare shop outside. I bought for 10rs and that will give u the perfect fit. I don't know wheather or not it is avaliable at OE. but u can try. you wont find part number in catalogue because the mudguard which is mentioned in old cd-dawn catalogue is fiber one. But actual it is iron metal mud guard. So tell them to give flapper for old cd-dawn iron mud guard and u will get it. And u need only two screws, dont use that bolt, buy these two screws (91508-GN2-000 screw pan 5x10.5) that will fit nicely and will look like OE fitting.

Your rubber kinda thing may got harderned and coming out. Get the new one at OE 45451-KCC-900 GUIDE, FR. FENDER CABLE.

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

[MENTION=29030]Pinaki[/MENTION]- although you have done a good mod but you have destroyed the mudgaurd. The easiest and best way is to get the RX 100 mud flap and paste it on the inside surface using fewi quick. Looks not out of place and also doesn't damages the mudgaurd.

@all- long time no update.

My Joy is running beautiful. Just that i am only riding it on week ends. It is quite dirty as it is raining here a lot. The chain sprocket is gone as i can feel the rumbling on the left foot peg. Also head and valves requires cleaning. Almost one DID timing chain has been changed but still head hasn't been opened. Also bike is showing a little hiccup at 55 kph most probably dirt in carburettor. Waiting for rains to be over for doing the work as new sprocket kit will get dirty in rains and will decrease the life.

Thought of going for 43T from DID being thin chains, but then thought that it is better to go with OE size of 42T as one of the things i like about my Joy is the smooth pull and zero sound at 60 kph, which i will miss on fitting 43T.

Already it has very high low end torque which just lifts the front wheel if ridden by in-experienced hands. With 43T it will cause wheel spin on loose and wet surface in first gear.

So it is 14/42 setup again which i will go for. Will go for Rolon chain kit.

Also the brakes need overhauling as the rear brake is sharp but the front brake is weak. Will change the front brake shoe and also will polish the drum with fine sand paper.

Bike has run 70k after changing to USHA bore kit, still compression is so hard that my younger brother still finds it too hard to kick start.

So i will update quick as planning to get the work done in next month. So the following works need to be done:-
1. Head cleaning and valve polishing
2. Chain sprocket replacement
3. Carburettor cleaning.
4. Front brake overhauling.

Bike is feeling rough and not smooth. All this will make the bike run like new smoothly.

Although bike feels rough, man the torque, after riding extreme, the bike just pulls as if on no load. With two up the torque is a great help which is bothersome in extreme.

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

Tried it , doesn't provide sufficient extension ( is short ) and required strength on the Splendors plastic mudguard . It is designed to be fitted to chrome cd100 mudguard with a metal brace and 2 screws - which is really flimsy way to fix anything on plastic base . The 3 bolt mount I have used is very strong and doesn't allow any lateral shifting at all ( to prevent plastic cracking ) . Most importantly for me , it provides sufficient extension and an angled end part that prevents almost any mud lifting into the bike at all . I have considered almost everything else available here and made careful measurements with each .

No the rubber ring is quite normal ( supple as new ) , it's just wouldn't stay put - that's it . Ok now .

Same problems with the Rx100 / Crux mudflaps . They are made of flexible material , are short and designed to fit onto chromed metal mudguards . Remember that I have had both these two bikes and I am very familiar with their parts - so I had considered it . No damage done to the Splendor's mudguard other than 3 small cleanly made holes in the lowest part . Also I have used very good quality washers on both ends . Thing is , it's working very well too - motor runs much cooler with the relieved airflow . Only fear I had was that it might hit a high or steep speedbreaker while comming down from it , or catch on the edge of a deep pothole while entering it . I have deliberately ridden the steepest breakers and deepest holes around here to test it - no contact yet . This Bajaj part is actually very well made for Rs 40 , check it in a shop and you'll see .
Guess we have the same weather pattern here since me too am waiting for rains to go for brake , bearings , fuel tank cleaning etc maintenance work . Also front fork service is pending , got the parts .

The other two small mods I have in mind is as you know hardwiring the bikes electricals , and fitting a set of rubber fork boots or gaiters whatever it's called . Diameter of the fork inner tube on Splendor is 50mm , and it's lacking the groove on the lower fork leg's top ( which is there on bikes designed for the fork boots ) . Still looking for which bike's part may fit . Wind-125's , ind-suzuki , GS150's , old pulsar's seems good candidates .

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

Shoeb, had once requested to hear the idling sound of my Joy with USHA bore. I had forgot where i kept the video but on monday i got it. So posting here.Here you can hear as it is shot at night on the day the work was completed. The idiling is with the idling screw completely opened out as after this how much you turn the screw out bike will not decrease idle. You can feel the strokes and how free the silencer is as i have taken the phone directly to the exit of silencer a couple of times at a distance of 1 feet from silencer.

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

Does all Splendor bikes come with open bearing on the sprocket carrier ? Mine was like this from factory . As far as I remember Yamaha had sealed bearings in this place too . Wheel bearings are of the rubber sealed type though .

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

Sprocket bearing is of open type but there is separate replaceable seal( facing towards the chain cover).

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

Apologies as i was away from this page from pretty long time , finally got my hands on carb of splendor and boy i was surprised , i never ever saw or knew how to open carb , read pinaki da`s guide and went for it

when i opened this was the condition of float


Yes there was a dead ant and debris in it . The bike was in garage for almost 2-3 months with fuel in tank .
So i went on cleaned everything with acetone and blew air using syringe ( yea i know it wont work )
Cleaned jets using toothbrush bristles and blew air through them.

Fitted back everything and took care nothing was left out .
Now some queries ..

1.There was a plastic part float maybe ? it had a very small pointed metal piece , what is this ??
2.I have seen people talking about pin position , like 2nd from top etc . Where is this pin ?

Rest all this is nothing as compared to fork job that i messed up big time

Fired up bike and OMG it idled like a gatling gun , revved smoothly , bit hiccups due to improper tuning . As compared to CBZ this has air screw so please tell me how to tune this using ears as i dont have tachometer

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

1.That is known as float pin... It cuts-off petrol flow to the float bowl after a level has achieved.
In simple words- the function of float and float pin is to maintain correct fuel level and prevent overflowing of petrol... Just like the role of ball-cock valve in a flush tank.

2. This pin is known as jet needle. This pin can be seen when you remove the slide & top. To adjust the pin, you need to remove the throttle cable's end from slide, remove a cir-clip and install it on the desired slot.

I must have posted photos of cir-clip position here long back but anyway I am re-posting it again.
This picture shows the factory position of cir-clip.


This shows of circlip 3rd from top.


As you move the cir-clip towards the top, mixture gets lean. I would suggest you to not touch this particular thing at this stage.
Tuning the needle jet is difficult as detecting the change in engine behaviour is difficult. Some engines run better when the mixture is lean, mine happens to be one such.
Air screw is exactly opposite of fuel screw... Anti-clockwise to lean, clockwise to richen. Follow sibun's guide.

Tomorrow I shall be posting a major update.

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

@ rohit - firstly nice job done . I think I can see a few drops of water in that float-bowl of yours - if so then there is water in your fuel tank too . Remove the fuel tank , undo the cover flap and drain it upside-down into a container . Dry the tank thoroughly and fit it back and refill dry petrol . I think you get the idea , ok ?

The white plastic part is the float - because it floats in petrol in there . And the metal thingy with a black rubber tip is the float pin . Together they form a valve that lets petrol into the float-bowl as soon as the level inside it falls - every time .

The pin ( actually it's called the needle ) on which you can move the cir-clip position ( that shoeb speaks of ) is attached to the accelerator cable where it goes into the carb . Better not to fiddle with it at all .

Lacking a tachometer ( and experience with telling rpm from engine sound ) I visit the hero service center nearby and they adjust my carb very well with their hand-held tacho . I use this as a good starting point and make small afr-screw adjustments from this if necessary , keeping the idle rpm fixed as such . Moreover they do this for free . You can try it .

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

Guys was away from this thread for so many days. My bad.

Some updates from me of my Joy.

Did much needed pending works on my Joy.

1. Finally changed the chain sprocket set. The last set lasted for 98k and still was not making any sound. But the movement had become rough. So changed it to Diamond Racing special.

2. The sprocket bearing was having a little play. Change that to a new bearing from TATA.

3. I was feeling that one of the valves was leaking. It was just my feeling and was not confirmed. When Head was opened the inlet valve was leaking compression. Polished the valves and resettled. Although the valves have run 70k but still has not worn out. Continued with the same valve.

4. Head was cleaned. Although had run for more than 35k after last cleaning still has not much carbon deposit.

5. Was doubting the SAI pipe to be blocked. And it was indeed blocked. Clean the carbon by heating and burning the steel pipe.

6. Changed the engine oil to MOTUL 3000 4T 20 W 40.

7. Changed the seat cover as the old cover has become slippery.

8. Changed the front brake shoe as it has become hard. Now braking is back to normal. Although changed the chain sprocket but rear brake shoe has hardly worn out so continued with the same.

9. Re-tuned the carburettor. Since compression has increased after valve polishing, needed a little more rich setting from before.



Since clutch plate was changed some 3-4k kms before so bike has become almost new. Only irritating thing is the slight crank sound on hard acceleration.

When the head was opened looked at the bore, even after 70k kms bore still has the honing marks and there was no wear on bore. Will run for another 50k without even changing the rings. Piston is still tight like new bore. If members can remember had used USHA bore kit for my JOY.

Someday when my mind will go awry will just buy a new crank, new bore, valves, clutch and plates, and will open the engine and fit everything back in 2 hours straight.

But since the bore is like new so not interested in opening.

Photo of the chain kit that has run for 98 k before replacing:-

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

Sorry for being absent here for sometime ... missing a lot of interesting posts here . My brother-inlaw is in hospital from crashing his new cbz-X under/ behind a long trailer ( which was parked with lights off ) at night while descending a bridge . He said that the brakes didn't hold - dunno how that is possible . His right elbow is crushed - docs are hopeful to save the arm .

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

Finally got one analogue tyre pressure gauge from a spare part shop. They told me that it will show a -2 psi from the pressure inside tyre. It has got dual readings in kg/cm2 & psi.Now it is helpful for me to adjust cold tyre pressure. In case of nitrogen filling do we have to follow the cold inflation levels?
.

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

Oh! extremely sorry to hear this. Didn't visit this thread for some days and when saw this i got the sad news.

Usually in night we have to be attentive and alert when riding. Even though the lights of the trailer are not there but still CBZ-X lights are very bright to show the road properly.

Anyways what has happened has happened and lets pray to god that he regains his normal life soon.

Brakes would have braked fine but i think he braked late as he would not have seen the trailer. In this 24k kms on my extreme i have never felt the brakes not to hold. It has braked fine and sometimes too strong that i had to release pressure on brakes to be able to steer the bike.

Ok, mishaps happens and may god bless him to get a second chance to live the life normally.Usually doctors will try to save his arm but pray to god as in times like this sometimes it depends on the all-mighty.


While using nitrogen no need of checking cold or hot tyre pressure as nitrogen hardly increases much in temperature.

Guys like shoeb and all where are you all. Once this thread which was the most technical thread is now dead.

Some days prior during the holidays got to go to the old job site to meet my friends. Took my Joy as have to offroad in river bed.

Bike pulled well even in second gear.Mileage is a little low after head de-carbonisation and this sunday will clean the carburettor and also re-tune the carburettor.
Also will give the bike a much needed wash and wax coat the bike after wash.

A picture of the bike parked when took it to my old work site:-