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

Six pulses because in four stroke bikes every two rotations gives one spark, so with six pulses that gives 12 rotations which is easier for the timer to calculate with respect to seconds, so the tachometer is designed for the same.Yes, the tanks have become so much costly now-a-days.For your shock absorb, open the top nut and pump it properly for removing the air.Also the left shock absorber check the springs will have been fitted the opposite way for the spring to make sound.

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Six pulses because in four stroke bikes every two rotations gives one spark, so with six pulses that gives 12 rotations which is easier for the timer to calculate with respect to seconds, so the tachometer is designed for the same.Yes, the tanks have become so much costly now-a-days.For your shock absorb, open the top nut and pump it properly for removing the air.Also the left shock absorber check the springs will have been fitted the opposite way for the spring to make sound.

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

Let me tell you about the bitter and worst experience I had with the ASC.I dont have any tools here in Tiruvannamalai.So i depend on the service centre even for a very small maintenence cause.According to that, i lubricate the drive chain for once in every 500 km.At that time the bike had done only 7 thousand kms. So, i went to the ASC and told to lubricate the chain only. I was put a job card and told that i would be charged Rs. 10. I said ok and was waiting in the customer lounge. In this ASC, the workshop and the customer lounge are separated only with a huge glass, so that we are able to see what is exactly happening there.Since, it is a job of just 10 minutes, i was watching TV there!! but after waiting for more than 30 minutes, the bike was not returned. I looked what was happening there and wondering why the delay. I was almost shocked to see the whole rear wheel assembly, brake shoes, the rubber thingy that is present inside the drum which is slightly dough nut shaped,sleeve etc were removed and put on the floor. My heart was beating like nothing, my arteries were about to burst!.Any how i didnt lose my temper and went to that stupid head mechanic and asked him the reason. He told the exact sentence. "Sir, your bike's rear wheel sleeve is worn a lot. It is a very important part. I wonder how did you ride your bike in this condition. So i have replaced it. pay the bill amount for Rs. 50." He showed the "worn part" to me. (picture attached below). Later on i came to know that by default, the sleeve has half flat surface and half thread alternatively. My mechanic taught me. Coming back to the story, I thought the head mechanic have done a very good job and started the bike. (here, you have to note the bike was not test ridden before and after the repair job. He is called the GREAT HEAD MECHANIC!!) The bike was struggling to move. It was feeling that i am trying to push the bike in 4th gear.Some how i tried to move the bike by giving almost 50% throttle. When i shifted to 2nd gear, the bike would jerk for a second and then move. The same jerk happened in next gears also. The highlight was,the bike was vibrating like hell. I couldnt even keep my hands on the handbar. I thought that it might be some other problem and rode it to home. Later that evening, me and my dad were riding. My dad couldnt keep his feet on the rear foot rest due to severe vibration. I told him the story. He took me to his mechanic (who later on became mine too!!) who services his tvs excel!. Mechanic inspected the bike and found nothing wrong. Since it was 9 pm, he kindly requested us to come next day morning. I was very much worried that night. My thinking went like this "i switched to hero honda only for the world class service they provided. But what have they done to me? Will the problem get cleared? or should i sell this bike and go for a new one? etc etc". The next day, i went to visit my mechanic by riding my vibratory passion pro. The mechanic greeted me (he was a good friend of my dad) and i was about to depart and asked him "bro, when should i come to collect the bike". He: Do you have any urgent work? Me: No. He: Then why are you going? Sit in that stool and lets try to find the problem. Me: Ok (with a sigh!!). He told his assistant boy to remove the rear wheel. I was watching it. He removed and was checking the sleeve. I dont know what he thought, he asked me the original sleeve which was in my bike before. Luckily, i was having it with me. (That was the only good thing the head mechanic did. He returned the sleeve to me when the bike was replaced with a new one.). My mechanic compared both the sleeves and gotcha!! The problem was caught. The new sleeve, which was put by that stupid idiot was 6 to 7 mm shorter than the original sleeve. My mechanic told that sleeves does not wear out so soon. Your sleeve is perfect in condition, we shall switch back to the old one. He changed the sleeve to my original one, completed the work, took it for a test ride himself and gave me for a test ride. That feeling when i rode it is unable to express in words. I was showing all my 32 teeth like eeeeeeee!! Man oh man! my problem got solved. The bike was butter smooth again! I was charged Rs. 30 for this job. I thanked him whole heartedly and went straight to tha Hero ASC. For my luck, the manager was standing in the sales area. I went to him, greeted him, hid my anger and started with a smile. Me: Dear sir, you and your people do a wonderful job. You make the perfect running bikes to stall and you create wonderful vibrarions sir. I dont know how to thank you etc etc.. (he understood that what i was trying to tell). He: Whats the problem?. I told him the whole story. He called up the head mechanic through the phone and started to scold him and shout at him. (We have 2 ASCs here. I went to the main ASC and that stupid mechanic was in the branch ASC which is 5 kms away).I could clearly feel that both manager and the mechanic were acting. It was just like a custom scold. I think these kind of problems happen here in common. Later on, i called dad and told him the matter that the problem have gone. He was happy and at the same time he lost his temper and with full force i took him to the head mechanic. Wow, my dad was yelling at him like hell and the mechanic's face was like....."man, i wish that i could be deaf". Then we happily rode home. The reason why i went to water wash to that ASC was just to test that head mechanic's pulse!!. After this incident, my bike was serviced 2 times by my mechanic and runs very fine, unlike that ASC mechanic!!

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

Sorry for being away from thread for so long,As you know it was confirmed that my bike was smoking and shocks were hard as hell. So after long wait i saved up enough bucks to get all this job done.

Now jotting down all the problems i had with my splendor

1.Pickup was low but not worst
2.Startup was pain, never started on time
3.Oil entering into combustion chamber
4.Forks were hard as hell
5.Timing chain noise and loose tappets
6. Fuel gauge showing full instead of correct reading <--- THIS IS STILL UNSOLVED
7.Feeble horn

So i proceeded one by one solving as in one day everything cannot be done
So first got shocks opened , Straightened and refilled
New oil seals and Valvoline Fork oil was used
150/- for seals
100/- for oil
150- for straightening
100/-for shock cleaning and steering bearing tightening

Total : 400/-

Now today went to mechs place and explained him issues

Head was never opened in 12yrs (42K on odo) and engine noise was high so were vibrations

Head was opened for examination and this was the condition


So mech examined the valves and one of them had play , so changed them to OE valves

Head was sent down for cleaning by lathe guy


This is cleaned head and new valves

Now i had assumed that piston rings are busted and need to be changed but mech said they can do next 10K atleast provided i use 20W50/40 but no w30

This was condition of piston , i could see some gap between cylinder and piston but wasnt sure it was under limits



Next up was clutch and timing chain change

For timing chain i had two options OE/Rolon so called up @sibun and he suggested to go for diamond but i had to resort to Rolon , sibun the OE one i told had HERO stamped so i didnt get hero chains are crap .



Plates had life for another 5K atleast but i got them changed anyway as friction material was getting aged

Now everything was repacked and greased , also rear wheel rubber dampers were changed.

New front tire was fitted , CEAT F85

This is old valve closeup shot


Now splendor is back to its early glory

Only few small things remaining , welding the centre stand , cleaning wiring connections and painting of tank (touchup +2K )

I thank each and everyone who helped me in this build , @shoeb.2015 , @sibun , @paul.1911 , pinaki da

One thing that shows about Hero was , when i was on verge of changing the battery , i saw the fuse was blown , one fuse blown in 12yrs this is what quality of hero , simply unmatched

Thank you everyone will be maintaining my splendor regularly now onwards

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

Hi RohIIT,

1) You could have made a Somender Singh's Groove near the exhaust port, when you have opend the head all the way. It works like a charm on the car I'm driving now. Very Very high low-end torque (some people have experienced a shrink in top-end by 5-10KMPH on cars). I can manage in gear 3 in smaller lanes and bumper to bumper traffics even at speeds as low as 10kmph + drastic mileage improvement from 16KMPL to 23 KMPL (I'm not trying to see the idea but this is my experience).
Be careful,
not to make a pre-ignition if you make the groove near the intake port,
atleast 5 mm away from gasket edge,
roughen up the sharp edges of the groove.
There are loads of pics on net to see so.

2) try Endurance (bajaj Discover has it as OEM & pulsar's have the heavy ones) Nitrox shocks from the dealer for the rear. It works like a charm.

Regards,
Sri

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

Good job ! Rohit .

Yeah , those managers and service center owners just pretend to scold the mechanics boys , I think it's an well rehearsed drama since it happens so often daily , they play this same game everytime they get caught bungling up a job like this . I insist on not sitting in the visitor enclosure and stand next to the job whenever I rarely visit the ASC . But even that doesn't work always . Feel sorry for the trouble you had to endure .

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

[MENTION=61630]jeswin[/MENTION]- The sleeve that the mechanic has used was from the splendor/joy bike which are of old model and was made from those rear wheel hubs that had thicker sprockets.But the passion pro uses the super splendor model rear hub and thus that sleeve is longer than our old model bikes. If the head mechanic doesn't knows this that means he is the greatest Idiot that i have seen till now in ASC.And those scolding drama is there pre-planned one as if the manager doesn't scold then the customer might complain to the Hero toll free number and then the situation will be different [MENTION=57344]RohIIT[/MENTION]- From the picture that you have posted it clearly shows that bike was running super rich. Also the valve seats are quite worn out, is somebody ridding the clutch instead of changing the gears.Also i had advised you to change the rings to pleasure standard rings for better compression and oil sealing. As for the timing chain try to search for DID as it is best. This is the second time i am using DID chain and this makes the engine sound like new engine [MENTION=67826]sri19022003[/MENTION]- As per my experience Hero's OE shocks are best. Hero shocks are little harder than Bajaj ones but this gives them better handling and also better control over bounciness. I have replaced my rear shock on Joy ones and the OE ones are again best. Hero supplies shocks to Maruti, Hyundai, e.t.c so you can know what is the quality. If softness is required then we can change to splendor pro rear shock as it has five step adjustable shocks.

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

[MENTION=28527]sibun[/MENTION] yes i talked regarding piston rings to mech, but he said currently the rings are 70% okay , they were leaking very slightly, so after 15k or so when I get slightest of smoke will change it. I am talking to other retailers for did chain but seems no one has it, so next time I open up head for cleaning, will change chain too along with rings. But for now I have to tune carb as I got it, it is running rich and hampering top end

Sent from my Nokia 3310 using internet

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

Yes, As Sibun suggested, Handling can be the best with OE.
Surprised to know that Hero supplies shocks to Maruti, I know the whole quality dynamics change for the 4 wheelers compare to 2 wheelers.

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

@All I have bit of problem, battery has 3V right now, and 12-13v at battery charging terminal. But still nothing electrical component work like there is no batt. Fuse is replaced but still same condition. Also fuel gauge shows full reading no matter how much fuel is inside tank

Please pour in your helpful replies

Sent from my Nokia 3310 using internet

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

Check your battery or the wiring. The fuel float component may need a replacement or type fuel gauge

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

Started riding my splendor 2002 for long rides.Bike is just 20k+ now.
Seat was not comfortable..Put a new seat cover with cushions Rs 280/-
The indicator was not blinking,also no sound.Replaced relay Rs 80/-
Adjusted clutch free play too.
Getting amazing mileage 80 kmpl.First time I am getting such a figure.Usually it was 55.
I guess change in riding style can affect mileage so much.I used rev hard in every gear before.
The headlight is not working in DIM.It is fine in bright.Why?

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

More than one cell of the battery is damaged. Replace the battery.
After replacing the battery, check the terminal voltage at 1/8th throttle and at 1/4th. Voltage must be more than 13.5volts.


Also do a parasitic drain test-
To setup the meter-> Put the digital meter in 10A mode, connect the Red lead of meter to 10A socket of meter.

To test
Remove the negative wire of the battery.
Attach the +ve red lead of meter to the negative wire of the bike's harness which attached to the battery.
Attach the -ve black lead of meter to the negative terminal.

Observe the readings when the key is in
1.Off position
2.On position
3.Engine running

Let me know the readings.

For the gauge which is showing full as soon as the key is turned to On position-
Check if the yellow wire is getting short with the green wire of the two pin connector which I told you over what's app.

When that two pin connector is removed, the gauge should show empty. If the green wire is shorted with the yellow wire then there will be zero resistance and the gauge will show FULL.
Just trace and follow it to the meter, it must have shorted somewhere. Most probably near the steering harness.

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Accelerate gently until the desired speed is achieved, you will be surprised to note the mileage. Disclaimer- you might sell your RTR . Just kidding.

Ok. By DIM do you mean the low beam or the parking/pilot light ? Just remove the bikini fairing and test or inspect the filament the both the bulbs. If it is has darkened then replace it.
I hope that the switch/contact is not loose.

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Slightly off-topic but as long as it is technical , I think it is permitted to post it here.

What is this somender singh's groove ? Is it patented ? Is it used in mass production engines ? Hearing this for the first time, sounds interesting.
Yours is a petrol car I assume. What is the make and model ?

You, PSR and Sibun - please explain the principle/idea behind this mod.

P.S- I will never try this on my splendor though !

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

Yes , he has a patent from the united states patents office for his mod - US Patent 6327579 . Acatually the thing is said to be the most effective in old design 4-stroke 2-valve engines like the Splendor's .

There is lots of material worth reading on this topic on the inter net . Start here - http://www.popsci.com/cars/article/2...rch-holy-grail

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

That was a bad time indeed. Are we customers allowed in the workshop? Thank you for understanding my feelings sir.

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Now only i have understood that "what is meant by accuracy". Even an mm could cause very much trouble. I have also decided to never ever visit the ASC at any cause. I have good people like you all here to help me. Thank you for the information on that super splendor's hub, as passion pro too shares it. You can see bigger idiots than him here! Every one including the police should be given a Ph.D for 'obeying' the traffic rules here.

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

I have a similar story about ASC. I noticed before third service that my bike is not hesitated after speed of 60 around 65-70lmph. So i use to reduce the speed from that mark.
I reported this during my 3 rd, 4 th service to ASC. But problem not solved they use to say me we inspected coil. Even check by swapping in magneto coil. Which recently i found not true as my bolts for cover of coil are not even touched. After 2 days i asked ASC to keep my bike for 2-3 days as i was out of station and inspect. Head mechanic taken it to his home around 20km away. Still as per them they never identified this problem. I shown them same. while bike is on mail stand. Still not able to solve and recommend to change magneto completely.
Even one of local mechanic was not able to trace same. After service ,Once i was driving bike at 65-70 kmph and my bike refused to run. It was moving with max speed of 20-30 kmph.

I showed the same to road side mechanic. He opened spark plug which was black. Cleaned made trail. Again same problem. His owner opened seat and found piece of cloth clogged inlet below seat. removed same and bike runs fine. Probably when i driven my bike at high speed it might got sucked in on that day. But earlier it was there and blocking air get sucked.

A bad experience. Now i feel that these ASC are just sucking money.