Replies in bold.

I am learning something new every day,thanks to Sibun.


Pinaki ji
As you can see that I have replaced almost every part and the bike is almost like new.(Except the engine)
I am looking for a new engine as 80% of engine parts are to be replaced.
Is it available ? Do they sell it as a complete assembly ?
(If available,will they punch my current engine number on new engine?)

Thank you for your effort and listing all the parts to be replaced and guiding me

How much did replacing everything cost ?

Around 14k.
The most expensive item was tires and rims.(5200) MRF Zapper.

I have never inquired about whole assembled engine , but they should be able to do that without any problems , including punching the engine number/ registering the changed number for you with the RTO . If most of the engine needs replacement , a new factory assembled one would be fantastic . You may even opt for an new engine with electric self-start then .You see that still the cost of the complete overhaul is quite reasonable compared to getting a new bike like this today . Almost every other new bike I see with my friends have some or other niggling persistent problem .... I am looking to buy another bike now but can't take decision just because of this . I don't want to buy any problem , at this juncture of life I am trying to simplify things and gain more time to spare for myself and family . Splendor is serving that purpose admirably for almost nothing .

I am looking for the "Old type" of engine without emission reduction technologies..

@ Sibun
Is factory assembled engine available ?

(I could make a small generator out of my old engine or practice overhauling )


Did you consider Honda CB unicorn ?
It is a no-nonsense , simple looking bike with an ultra-reliable engine.

BTW,What are your requirements and what type of bike do you prefer ?

No on line store sells it as it is only RS. 10 for a tube.Can you tell me where you resides.

Diamond has both factory and regional office in Hyderabad ask some spares shop owners.

Do not sell your splendor as it is your first bike. I decided to buy an extreme in sep 2006 but my father said me to sell my joy which i didn't agree. so i waited for 5 years and bought my extreme in sep 2011 when i joined a job because i will never sell my joy.I thought my extreme will run more and joy will run less and i will give it rest as it is 12 years old but instead i love my joy so much that i ride it more than my extreme. Joy runs for 2500 km a month and extreme 1500 km. Your P200NS will perform much better but will it last for 10 years like the splendor or will it evoke the same emotion as splendor. The fact is that any bike you buy afterwards you will not feel the same emotions as with your splendor.

Oops,I didn't knew it is called as TIDC.

Check it out.
(It has a maintenance and trouble-shooting section along with loads of info. )

Yes diamond chain set are produced by same manufacturer as BSA and HERCULES cycles. It is TI cycles and chains.

No, a new engine is not available and a new engine cost about 20k.
Usually overhauling a engine completely cost Rs. 6000-6500.Do not go to ASC as they unnecessarily change many parts and bill around 10k.
Whenever opening engine do a complete overhaul.
Always change the following during overhaul:-
1. Bore kit- Change to USHA kit. Do not use original. If using original kit throw away the piston as it is completely shit. Use USHA standard size piston lit with original bore or go for USHA bore kit. cost-Rs.1450.
2. Valve kit- Change the kit which consist of both valves and oil seal. Use a lapping compound from waxpol and polish the valves to the seat.Hero honda camshaft do not wear out unless driven with no engine oil. My camshaft was changed at 3 lacs km that too it had some scratch marks only. Still i have kept the old camshaft as it has no problem.Cost- RS.360 for valve kit.
3. Clutch section- Change the clutch housing,clutch plate, clutch center, Gear pinion teeth, pressure plate and springs. Cost- housing(1061),plate( use makino cost-200 and last same as original), pressure plate(72), clutch center(250),GPT(160), springs (120).
4. Timing section- Change big roller,small roller, push rod,rubber & spring, oil pump sprocket, and timing sprocket. Use DID timing chain(check for original) as it was supplier to hero when japan timing chain was used. If couldn't find DID use diamond/rolon. Cost- RS.450 for timing kit and Rs. 174 for DID chain or Rs. 100 for diamond chain. Do not use original.
5. Crank- Here showroom change the complete crank for Rs. 3050. But complete crank change is waste of money. In my bike no crank change is done till now. Instead change the connecting rod, big end bearing, and the main bearing which supports the crank. Take it to good lathe workshop and reset the crank and use MB or HR connecting rod. Use skf main bearing.The main problem is determining what size con rod is required - std,1st oversize or 2nd. Cost- con rod- Rs.600 and main bearing - Rs.340.
Do not change any gears from gearbox as it doesn't wear so easily. When i had opened my engine for connecting problem at 3 lacs km the gears were still new and will last easily for another 3 lacs km.
Do not open the oil pump as it doesn't require any overhaul and once opened you have to use new one.
Change the neutral patti on the shifter fork. It is a copper strip and cost about Rs.15 and is used for neutral indicator. If it breaks then there will be no neutral light and you have to open complete engine for it only.
Use kerosene to complete wash the engine and after washing put some oil on the crank bearings for preventing rust. Do not change any other bearing other than the crank (main bearings). all other bearings do not wear out so soon.

Thank you very much.

Where can I find this DID timing chain ?Is this jap made ?Is it Daido Kogyo ?

How much is the gap between the two inner sides of the crank(In mm) ?

Splendor Plus - xBhp Motorcycle / Accessories Reviews Database

Valves lapped and grinded (using a grey color lapping compound),

(On inspection with a bright light a very tiny hole was visible from other side)

Total cost -Just Rs.100 including removal and refitting

valve grinding ... hmm ... sounds interesting , Any pics ?

If this is of any use to someone..............

I am going to buy a used engine for Rs.2500/- to see whats inside
(Experimenting with a used engine is better than experimenting with a perfect running engine.)

Great idea for the price ! I am sure you can get that engine running perfectly well all by itself too ... these engines are so simple & indestructible .
Alert ! 10w30 synthetic motor oil (Jaso MA) for 300 bucks only , check the engine oil thread , have posted pics there .