My friend Is using the front portion of platina lever in his passion pro,so i think it's a direct fit,and its easy to shift too.

Its the same as the above picture,the back part was cut away

Somehow got the valves out,cleaned it,valve seat lapped but unable to compress the springsto put back the keepers .

How to you compress the springs Sibun ?

(I will get a spring compressor only as a last option )

Go to any authorised Hero Honda dealer and ask for CD 100ss gear lever. You will get it.

If you have another person then it is easy. First place the spring, the valve top washer and the lock on the washer. Then insert a 10 No. flat ring wrench from the top cover side and use the ridge between tappet hole and top cover as a fulcrum. now push the valve using the wrench by pulling the other end of the lever up so that the wrench pushes down the valve springs due to the fulcrum from the support. As the spring compresses the the lock will go down and tell someone to adjust the lock by a thin screw diver so that the locks are straight and close to the valve stem. Now slowly release the pressure, be careful to slowly release other wise the lock will not engage. Now remove the wrench and hit the top of valve step 2-3 times hard so that the lock engages due to vibration.
Joy has more torque because-
1. The combustion chamber has less depth than splendor so compression is high.But the downside is than every 15k kms the head has to be De- carbonized as little carbon causes knocking.
2. CDI is different so ignition timing is different.
3. Piston is longer than splendor.
4. Magnet is heavier than splendor so more energy stored in the flywheel.
Due to more torque Joy uses 42 teeth rear sprocket than splendor 43 teeth.
Insert the 10. No. wrench from the red marked end and use the blue mark as a fulcrum resting the wrench on the top of the valve lock plate such that the lock is visible through the hole of wrench. Now pull the wrench up on the red mark side and the valve will compress on the yellow mark side.

I used the same trick to remove the keepers,I also took a multi-screw driver and put it through the magneto hole to make the screw driver magnetic.
The spring and washer was stuck to the valve so I had to hit it with hammer to break it loose.
I used a #14 ring spanner.
I will try again with the help of my brother.


Is there any noticeable difference in pickup between splendor and joy ?
Can it be interchanged with splendor's bore,piston,cdi ?
Is the length of con-rod same ?

Can you post the bore X stroke spec of joy ?

Bore and stroke is same as splendor.
The difference is the piston skirt is longer in Joy.
Yes you can interchange the bore and piston between the two bikes but you have to change the fuel supply from carburettor and this is very difficult.
The length of con rod is same.
No, you cannot interchange the CDI because magnet, stator plate, wiring, everything needs to be changed.
And believe me it is difficult to source joy parts like RX series.
I usually give the list of parts to my retailer friend and he orders it from his dealer by giving my chassis no. and engine no.
Yes there is noticeable difference in pick-up in both the bikes.
Splendor along with its lighter weight and bigger rear sprockets has greater initial pull till 50 kph but after 50 kph joy will not only cross splendor but will effortlessly continue to increase the gap. While a splendor will stop at 95 kph on speedo joy will go till 110 kph on speedo.
My mechanic and the showroom mechanic(only free servicing for my extreme after free servicing its me or only my mechanic,i never go to service center after free service) both agree that joy was one of the best products from Hero Honda but sadly the market didn't accept it.
While opening the valves it is easy. Take the spark plug wrench and cover it with a cloth and hit the top of stem with a high force. The lock will open. The purpose of covering the plug wrench with cloth is to prevent the locks from flying away with the spring force.
Chheda Electronics & Electricals Pvt. Ltd.
Have a look at the url posted. It gives the difference of splendor and joy CDI. also you can find the ignition graphs in the pdf files.
For those unsatisfied with headlight brightness, i have done a modification some 2 years ago which i will post in my next post.
Master ignition is the OE supplier to TVS for CDI and power is OE supplier to all bike companies as their is no one else in market and believe me Power has the best ignition coil in business which no one can match.If you ever find difficulty in finding OE ignition coil go for power.

Fuel supply from carburetor ? Whats that ? jet size ?

Can you post the pictures of joy's cdi,magnet and stator plate ? Please...... I want to see it.
Is it same as old(1990) cd100 engine ? Because I noticed that magnet was considerably heavier and stator plate was completely different from splendor's.

Thank You Sibun,if you had given me the link earlier it could have been a great use to me but anyways..........
BTW,How do you find these links ?

Still waiting for your next post to fix my crankcase,do post your headlight mod also.

@ALL-If anyone is going for coil re-winding,rewind only the left and middle poles and leave the right most pole untouched as it can interfere with ignition charging coils' performance.
You can easily get upto 2 amps extra by rewinding only two poles.

If anyone wants a kill engine switch -just connect one end of the a switch to ground and other to pin no 4 of cdi.


I request all members to post any link/info related to the bike here,someone could benefit from it.

At-least now I can power up the old cd 100 engine easily after getting the cdi connections diagram. otherwise I would have to change the stator plate.
(It is a 1990 make)

@ pinaki Ji
Can you check if your splendor has a four pole stator coil ?


They also have a solid state flasher relay.

I am using this one and this is my 3rd bottle . It contains 100g and costs 100 Rs here . Other than when I clean carbs , I use it to clean brake-drums & disc , electrical contacts and many other parts, works amazingly good on dirt /gum/adhesive & sticker residue/brake dust/hardened-grease/old thermal-compound/dirty spark-plug etc etc, harmless on plastics & rubber if you don't let it soak for any time , takes out paint instantly . The spray and nozzle extn makes it easy to apply in deep and difficult places .

Much as I love it , I am a practical guy . To hunt for parts for it and mechanic and maintain it is become too difficult here now . I can either keep my job or the bike running . Thank you for the generous offer of course .

I've not had the heart to take this bike beyond 75kmph yet , that too on a slight downward incline . The speedo is reluctant to move past 60(I felt) , after that it(speedo needle) becomes very very slow . I don't believe mine will do 95 . However I'm not unhappy for that , I am a bit unhappy about the lack of low-end torque , which necessitates frequent gear changing in traffic . I got this bike mainly to tiddle around the city to run errands .

Thanks a lot for your review.

OT
BTW,Whats there in the background ? I also see mobile cleaner(isopropyl rubbing alochol ?) where can i get that ? and some boxes of sleek ??? .....,it looks interesting. Do let me know about it.

OT

Those enamel trays are for processing photographs(prints) , this used to be my darkroom when I was doing film photography professionally working for a daily newspaper . I have retained all my film cameras/enlargers/lenses and development/printing equipment hoping to take up amateur film photography again when I retire and get back my lazy days . Since the demise of film photography , this is my multipurpose workshop . Plus loads of other misc stuff have gathered here since I also work on computer & networking hardware & software here and repair them .
You can get that isopropyl alcohol cleaner(20Rs only) from any big electronics market/shop in your locality. In kolkata I get it from chandni-chowk market . The other small boxes are sleek brand 3-pin plugs . I keep them in good stock since none of the shop-bought power cables for PC/LAN switches/Routers/firewalls/wireless-AP etc industrial equipment fits our standard wall sockets well , many of the equipment I get is imported and comes with US or EURO type plugs . So I replace the plug end with these 3-pin plugs as soon as I get any new equipment to install or repair . Plus a bottle of anti-septic lotion - you know why .

Any updates on the CD100 engine over the weekend ?

Finally , I've considered everyone's advice and decided not to sell of my splendor My mind didn't allow me to let go of it that easily.
So i've decided to use it for another 10 years (we will see what happens after that ).

Anyway I'm going to do major refresh work this week on my splendor and I need all the help I can get from you guys.

Notice that my bike has run just 70 K kms. What are the things that I should replace ?

I'm going to change my splendors head to Fz ( no comments please )
Need to change the battery (Tell me how to do this in a DIY way)
Changing to Alloy wheels
Going to change the bulb to Xenon (umm..white light..? throw some light on this please..i have seen many splendors with this)
And finally going for an Angel Ring (Not the projector..just the ring of neon-like light )
And ofcourse I'm going to repaint it fully..so should i go for old black colour or any combination of colours? sticker job will be done and won't be the default stickers.
And recently Is there any other exhaust which I can use with my splendor? (Many of my cousins & me have burned our legs because of this exhaust.)

[A company which focuses on total bike , car conversion and mods in kerala said that they can totally remodel my splendor to look like Fz / A new naked look -but ofcourse i said no ]
+: And do tell me how to clean my carb.The mileage has dropped drastically . When ridden in economy mode (40-50kmph in 4th with low Gear changes and braking ) my bike returned only 58kmpl .

Depending on the condition of the engine you may have to check with mechanic or Hero service if you need any of these .
i) Cylinder piston kit plus other engine parts .
ii) do a head decarb and valves service . timing chain .
iii) check the frame etc for rust and repaint where necessary .
iv) clean the oil filters and check the clutch assembly .
v) new set of tires, tubes and rim-tape(patta) . wheel truing and tighten the spokes (read back on this thread for my guide on servicing the rims).
vi) replace all 4 wheel bearings and 1 sprocket carrier bearing .
vii) a chain & sprocket set .
viii) steering column service and new bearings .
ix) a new spark plug .
x) just buy a new 2.5ah 12v battery(exide), it's a straight fit .
xi) replace headlamp reflector and lens with Splendor+ set and fit Phillips 35/35 halogen lamp . Avoid bluish tint lamps .
xii) new air filter elements . Brake drums & pads . All cables . swingarm bush , speedo pinion, a bottle of engine oil, gaskets, a tub of good grease etc etc small things .
xiii) clean the fuel tank , replace fuel filter inside it and clean carb (read back on this thread for my clumsy's guide on cleaning the carb) .

The list may be long but all these are simple to do all by yourself with a few simple tools over a few weekends . Bike will be like new and ready to tiddle around for another 1 lakh kms .
I prefer wire spoke wheels myself , they are lighter , flexs, don't bend or crack easily and can be repaired and looks kinda old fashioned nice . Also you can just change the brake drum when worn .
As for paint , I am wanting to paint mine an overall olive-drab or khaki like mil utility vehicles, when the time comes and I don't think angel rings will go with that, so I dunno .
New exhausts come with heat-guard which will serve your purpose . Check which type of exhaust you need , read this thread backwards for Sibun'jee's explanation of the topic .
Lastly , yes .. this is an fill-it-n-run utility bike , decent enough for the purpose by it's simplicity and has no pretense .. better keep it like that . Like elsewhere in life, the simplest virtues are the hardest to come by . And who needs to run to the office or grocery shop at 100kmph ?

I won't need new tires as i just changed mine Rest is all a must buy i think..though the engine is still in great condition and i don't know whether i would require any engine parts (Never ever had any problems with the engine..)
And yeah..the angel rings..!!!! I think they'll look well with the Fz headlight and if they don't , ah..who cares? ! and do you recommend i go for spoke wheels? I mean my rims are to be changed anyway (lot of rusting and bad paint because of my father! ..can't blame him though..its his bike )..And do you think that cleaning the carb and the fuel tank may get me mileage The AF ratio and idle rpm is just right..so i dont want to fiddle with those.. Thanks for your reply pinaki ji..

Yes ,I do prefer wire spoke wheels and I know that it is odd today .
If the rims are rusted from inside this may help - http://www.xbhp.com/talkies/motorcyc...tml#post604383
Try same trick with other rusty spots . Clean with kerosene & steelwool . Emery paper. Then redlead oxide primer, dry. Hard enamel paint, dry .

This how to throughly inspect and clean the carb - http://www.xbhp.com/talkies/motorcyc...tml#post701796
The shortcut (practiced by HASS) is to just take out the float-bowl by removing the two screws with a very short phillips screwdriver from underneath, and clean it and the jets with carb cleaner spray. All this with the carb still mounted in it's place and hanging in there .

Fuel mileage depends on so many things that it is difficult to tell. But if you carefully check most things I have listed , it'll surely improve .

I got a valve spring compressor and finished the top end,got to fix the crankcase now.

As your bike has done just 70kms,First replace the clutch plates,steel pressure plate(if burnt)and clean the centrifugal filter.
Then open the head and decarb the piston crown,head,valves and ports.

Re-paint it using stock colors,that way your bike will look original and you will not have any problem with RC also.

If you are cleaning the carburetor yourself-replace all the o-rings and do not over-tighten the flange gasket bolts,if you over-tight those bolts,the carb will warp and the piston slide will get stuck

Replacing the battery is very easy,just get a new 2.5ah batt.,remove the RH side cover, remove #10 bolt which holds the battery latch,remove the old battery,connectors and replace it with new one.