Thanks.

What about THIS ?

It is because your chain is worn and after heating they are binding together. Don't go about opening the engine for trivial matters. And please do not open the engine on your own as you will be not able to rebuild it perfectly and this i am saying after opening more than a dozen engines which includes splendors,joy, pulsar, extreme of my friends and me. Four stroke engines are quite complex to overhaul.

You can use BRITE-O from pidilite which comes in tube of Rs. 10 and is excellent for polishing brass,chrome,steel e.t.c. I polish my chrome parts with it and also have polished some old brass utensils at home and it removes oxide from the surface and restores new shine.

I wont open it myself

I have to get the following parts replaced soon.
Clutch bell,(It is causing dhak-dhak sound only when clutch is released.)
main bearing,
head gasket,
cylinder gasket,(leaking oil)
new jets or new carburetor(if replacing jets doesn't work),
valve seat grinding/lapping,
valve stem/seal replacement,(Leaks oil in cylinder if the bike is not used for 2-3 days)
tappet adjustment,
con rod bearing/con-rod replacement.(It is making excessive knocking noise)

Other non-engine parts-Rs.3000/-.


@pinaki ji and sibun

As this bike(HH passion) is mainly used by my father who wants a trouble free and comfortable ride -
Is it worth spending more money to fix it ?
or
Sell it and buy a new one?

Please also note that we(me and my father) have an emotional attachment with splendor and not with passion so based on this What is your opinion ?

Problem with all these polishes is that they contain some abrasives to peel away the oxidized/tarnish layer . So if you try them on a clean new chromed area , you'll see on close inspection that a very fine mesh of new scratches have appeared . If the damage is already looking ugly ... you can try it . Waxpol's silicone polish has no abrasives , and it cleans as it polishes . Only problem with it is it doesn't last an week .
Definitely worth an overhaul . This bike is an faithful friend and fulfils all practical needs, parts are cheap and plentiful, overhaul work is simple to do .. a good overhaul would give it a fresh life for little money ... while it is impossible to get this kind of quality build jhanjhat-free bike in the market today .

Urgent help required

Regarding HH Splendor.

Sibun I need your help urgently.

The kick lever had started to slip ocassionaly sometimes back but now the kick slips more often.
It sometimes makes a loud khat sound(as if something broke) and slips.(It happens mostly in the morning)

Is it a broken/worn kicker ratchet ?
I read somewhere that to replace the small &cheap ratchet-complete engine has to be opened.
Is it true ?
What else can be done ?
Shall I replace it ASAP or wait till kicker doesn't work ?
What if the metal pieces break and fall in the engine ?

The bike has run only 15,000kms in last 8 yrs
Engine ,clutch and gears are in showroom/excellent condition and I am not willing to get it opened.

Please help.

A splendor kick ratchet doesn't wear out so soon. A kick slips in splendor signifies your clutch plates have worn out. Change the clutch plates and pressure plates and you will see that the kick slip will stop. It is because splendor kick operates through the clutch and thus when plate wear out they slip. It is a sure way of determining worn clutch plates. It slips mostly in morning because in morning the bore is cool and thus the piston is tight and thus the kick slips.

Thank you.

I will change the clutch plates,steel pressure plates and springs.
But why is it making a "khat" sound every time it slips?

Can please you record a video/sound of your engine running at idling rpm and upload it on youtube or email me?

OT-
I found this on YouTube.
Hero Honda 30 seconders 2000 - YouTube
Skip the first 45 seconds

Finally , the time has come to sell of my splendor which was bought back in 96.

Has run 70K kms..
Stuff that was changed overtime : Silencer , Stock air filter (replaced with K&N and did jetting , so changed sparker too) , Rear drum brake shoes , removed the saree guard , box.etc , changed the visor/head to Fz's [bought a chinese one that was made for the Fz for Rs.400) , Speedometer+odo (stopped working sometime back and had to change it..).

Before selling i will reset everything to stock.

The top speed i hit was 105 (still had more ... )
Getting a steady mileage of 60kmpl when in city..and 70+ when on highways..

What is your main reason for selling it ?
IIRC,96 model splendors were more powerful.

I had made my mind to sell our Passion+ 2005 which has done 2,05,000 kms but Pinaki ji advised me not to sell it.

I am in the process of overhauling it and restoring it fully,yesterday I spent a lot of time servicing it myself and there is a huge change especially after changing the worn-out jet.

Parts changed/cleaned.

1.Keihin Pilot jet #38 (~Rs.250-300/-)
2.Carburetor Flange o-ring.
3.Carburetor o-ring.
4.Float bowl gasket.
5.Oil changed to Motul 3000 4T +(200)
6.New chain and sprockets.(530)
7.New Air-filter Element B
9.Fuel tank cleaned.
10.Petrol petcock sediment bowl/filter cleaned.
11.New Lighting coil.
12.Clutch lever play adjusted.
13.New front brake shoes.
14.AFR tuned.
15.New spark plug cap.
16.New Spark cable.
17.Rear Hub Drum rubber.
18.Front and rear drum cleaned.
.......
..
...
..

Hero dealer is now selling spares over the counter(I Dont know about other states/cities, at-least the one near my home is selling)
While the part keeper was searching for the parts,I noticed a "stock list" and found out the price of Chain kit to be just Rs.417 which actually sells for Rs.540/-

Even if we include 14.5% tax they are getting a profit of at least Rs.50 by selling each chain.I didn't knew that there was such a huge margin.

No, 96 model splendor are not more powerful. It is just that his bike has run only 70k kms and thus his engine has not much worn out. Even my joy easily touches 110 kph regularly. There is no difference except that the quality of materials were good than they are now.
Usually the jets don't wear out unless somebody has forced wire into it which would have changed the size of the hole.And you have made the right decision in not selling the passion. If my joy is running much better than new bikes after 3 lakhs km then why not your passion.
The parts list that you saw will be old but recently the parts price were increased by 20-30 %.
Why did you change to original chain sprocket kit. Check the chain if hero is written then be sure your chain set will not last for more than 15k kms.
If it is rolon/diamond then it will easily last for 40-50k kms. Instead you should have gone for rolon or diamond chain kit. My bike has diamond kit which i regularly clean every 5k kms and lubricate with gear oil and this set has run for 78k kms and still also the sprockets are as good as new. Usually my chain sprocket last for 60 k kms but this has run far beyond and will continue for another 10k at least.
@paradox- can you tell me what size main jet you have installed as splendor has largest size among all 100 cc bikes. size is 105 stock.

@ sibun any online purchasing web or store to get Brite-O ? As checked in local market but not found it . Pidillite dealer says its comes under crafting check book store , checked all but none have it except one who said he have it previously but due to less selling cancelled the agency & returned it to pidilite .

@Sibun.
I returned the chain and got a credit note.
(The shopkeeper is friendly and understanding)

Where can I get a Diamond/rolon chain ?
I saw a diamond authorized dealer somewhere in Hyderabad but I dont remember the exact location.
Google search is of no use.

@Sibun
There are many things which can go wrong while doing a engine overhaul.
Can you list some of the common mistakes in an overhaul ?
What care must be taken to avoid it ?

My July 2010 Splendor+ came with Diamond brand chain , so presumably they(HeroMoto) is supplying it yet on some models . Find out the HeroMoto authorised parts stockist for your city .. these guys are a treasure trove .
Same on overhauling , make a preliminary list of the necessary parts and try to get OEM parts mainly (unless an aftermarket item is vastly superior to it suggested by sibun'jee from his experience) . Go about it without hurry and with a good mechanic . If you can't get a very good mechanic , better entrust the job to the most reliable HeroHonda workshop , they guarantee their overhaul work .. parts & labour charges are categorically listed by HeroHonda and not more than the market .
Some parts that usually need replacement at this mileage are :
All gaskets , oil seals & O-rings .
Clutch plates , springs , clutch basket(if worn) , clutch cable & return spring .
Tyres & tube , Truing of the rim to be done and spokes tightened and bend/worn ones replaced . Inside of rim painted with lead-oxide primer .
4x Wheel bearings ( Single side rubber sealed 6301 size NBC or SKF made) and 1x Sprocket carrier bearing (this should be same 6301 size but both way rubber sealed) .
Cush-drive rubber blocks(if worn) .
Front shock absorber Oil , seals and springs .
Bearing balls in the steering replaced , also racer if worn .
Chain+Sprocket set Diamond make .
Swing-arm bushes - replace .
When bike is dismantled check the frame for rust/bends and repair/repaint as necessary .
Replace wiring harness & battery if worn.
New spark plug , plug cap & wire .
Throttle cable , throttle slide and needle - replace . open clean and regrease throttle spindle .
Seat - remove old cover and make new one with more foam padding .
Engine - Decarbonise everything . OEM cylinder & piston kit(pref USHA make) , valve set , seat , guide & springs . Valve seat grinding work . New Rod & Bearings . Preferably new Exhaust pipe .
All stand springs & rubbers .
Drain & clean fuel tank . New cap . New petcock, fuel filter & pipe . Carb seals,float pin & jets .
Brake shoes (ASK make ?) & drums/springs if worn . Brake cable front . Speedo cable & pinion .
Air filter elements A & B .

@Shoeb - Reason for selling = I won't use it anymore after getting my new bike delivered on may (200NS). In my family i'm the only "biker"..everyone else drive their cars ..Maybe i'll give it to one of my cousins..still haven't decided..A used vehicle salesman quoted 25,000..
@Sibun - I'll check with the mechanic and reply.It was him that did jetting.M not very familiar with the whole 'sparkers' thing (before doing jetting , the bike's engine used to turn off automatically..now it has a little better pickup and engine is as smooth as ever)