Any pics to show ? I've never really seen the internals of the head and the valves timing chain arrangement in a horizontal engine like this .

Fantastic ! those cam lifters are tiny !!
You had to clean up a lot of carbon and deposits I guess .
Did you polish the piston top ? How did you do the cleanup , and what worked best finally ? valves ground ? How ?

I soaked all the parts in diesel for two days and then used a brush.
I also used sandpaper to remove hard carbon deposits from Piston and cylinder head.

Exhaust valve was leaking ,so took it to a friendly mechanic and got the valve ground using a round shaped grinder and some lapping compound.

@shoeb- The head is quite dirty. clean it with a scrapper so that the head shines like new metal. Regarding lapping of valve you can use a drill machine to lap the valve. Take a thin petrol pipe of about 20-25 cm length and after inserting the valve fix the pipe on the valve stem. Now fix the other end of the pipe to the jaw of the drill machine and and apply the grinding paste on the valve seat. Pour some kerosene while lapping the valve to serve as a lubricant for the grinding compound.
Regarding the crankcase find a lathe who use to work on bajaj scooters(chetak).
No matter be it hayabusa engine or R1 engine but chetak engines are most difficult to work in.Chetak engines have to be aluminum welded at engine overhaul and grinded which is a precision job because if it is not done properly then engine will loose compression. I do not want to go into details of scooter engine rebuilt but they are the best guys to fix your crankcase.
And do not go about changing the timings of your splendor otherwise it will make your bike UN-ridable. Yes joy has the same magnet as 90 model CD 100.
@ pinaki- From your description, your splendor is loosing compression through the valves. Most new bikes from Hero and Honda are coming with this problem. Due to this problem bikes are under performing. You can solve this by cleaning the head and polishing the valve seat so that the engine is retaining compression.
@paradox- Congrats your decision on keeping the splendor and also congrats on your P200NS. Please post your model of splendor and whether you want to do full restoration or not of the bike. Then i can guide you including the cost involved and how to do it.
@all- It has been mentioned in manual that splendor series engine has a plug gap of 0.6-0.7 mm but with my experience it runs best with 0.8 mm gap. So increase the gap to 0.8 mm using the feeler gauge and see the difference. With 0.6-0.7 mm gap the bike feels strained at high revs, but with 0.8 mm gap the bike feels free to rev as spark is fired better. Do this little mod and post the results.

@Sibun- Thank You.

@Pinaki ji- I know you can easily open the head ,de-carb it and lapp the valves yourself.
It is fun to do and you can do this job 1000x better than the ASC .
Special Tools needed
Valve spring compressor


The job is fairly simple,takes approx 1hour for a beginner.

Consumable parts-
Cylinder head gasket(Metal)
Oil O-ring kit.(Rs.12/-)
Lapping compound.

Here is the detailed procedure.

1.Remove the timing sprocket cover.
2.Make sure the piston is at tdc of compression stroke,timing sprocket has a small circle which should align with a index mark on head.
3.Remove the side cover #8 bolts.
4.Remove the two #8 bolts holding the timing sprocket.
5.Remove the center dowel and the sprocket and chain will fall .
6.Remove the #17 tappet cover bolts
7.Remove the cylinder head to block anchor bolt (#10)
8.Remove the four bolts and washers on rocker cover.(Note where the copper washer goes.)
9.Pull the head and tap gently on the sides if stuck.
10.Use a valve spring compressor to compress the springs and then remove two keepers.
11.Remove both inner and outer springs.
12.Make sure the flat washer is still in place or take it out and don't forget to put it back.
13.Decarb everything,inspect rocker arms,cam,valves and lapp the valves and seats.
14.Replace all oil seals,head gasket and other packings.
15.Check and align timing marks.
16. Adjust the tappets using a feeler gauge.
Installation is reverse of removal

Yes , I am planning to do head-clean & valve job(possibly with new valve-set) @15000-20000 kms , maybe this winter. I too feel it is strange that engine is heating much yet at 10k kms and bike is reluctant to go over 70 kmph . My old Crux goes to 80+ without me wanting it even . Anyway , other wise the bike is veryy smoooth and easy riding, no noise and click-stop gearshifts, light and easy controls . Fast and fun enough to scoot around the congested city suburbs where I live. And nowadays I'm taking the cbz-x anyway for the longer weekend trips to hometown. So I'm going to just keep riding it like it is for 5-10k kms more now . And ohh , even yesterday another biker on a new pulsar180 made a u-turn to admire and ask me how much I got it for, thinking it's new bike , or was he envying a Splendor because of the new petrol price ?

= LOL
Petrol now costs Rs.81.44 per litre in Hyderabad.

As I don't find any other place to post, I find this is the suitable place to ask the query....

In my home, I hold a HH Passion 1st generation (spoke wheel) bike which is used as a backup bike in the last 10-11 years....where several 125/150cc used as a primary bike by family member and me and they are come and go time to time.

Due to act as a backup, this machine clocked a very less KM during it's lifetime.
which is now something 58,xxx KMs

The problem is several OIL leakage from different point & if that fixed then again from some other point. The major problem encountered last year was Engine oil leakage from the draining bolt which now solved by a local mech,but after that he damaged the alternator anyhow he recoil it, and it improved the intensity of light by 1%.

Now the problem is that the recoiled alternator is not able to charge the battery anymore and specially if the Headlight in use.....It is dangerous to drive with muted horn.

To solve this problem I think it need to replaced by new one, but querying to spare-parts shop I came to know there are 3 types of alternator available for HH passion and I need to quote the exact model number so he can place an order.....I can't gather that info till now,please help....where I can find this info.

My local mech not sure that if it will solve the problem...as he said it going to cost over 1.5k.

------------------------

The showroom/ASC (major in that time) of HH where this machine bought almost nearly shutdown by neighbour Yamaha showroom by their FZ sales and they don't bother to entertain anymore for such old machine, Earlier I ran into them for some spare & the ASC told me buy a new bike.

My another question how much going to cost a 1st Gen HH Passion for overhaul if I find any ASC to agree to do that....Can any 1 predict the total cost ?


The problem need to fix oil leakage from the right side of the engine block & the alternator need to replace (as this I assume)....thats all.

Please help..........

@ Neel
The alternator or generator costs only Rs.188/- and not 1.5k.
You can also replace it yourself if you are good with tools.

Can you tell me which type of alternator does your passion have from the images below ?



Or this ?



Can you post some pictures of the engine from where the oil is leaking ?

How was the alternator damaged ? Did the mechanic replace the crankshaft-stator oil seal and in the process damage the coils ?
Do you replace the crush-able drain bolt washer every time you change oil ?

Post some pictures so we can help you.

this would be the correct place to post this Neel , as these bikes share the same engine and general parts . Also I don't think there is an separate passion/CD/Joy/Cd100 etc thread .
I have suffered from the same thing with all my earlier bikes, the mechanics here are like that only . You visit them for one problem and they add another two to the bike . Happens every time, without failure . It is an repeated old story here and I am quite familiar with it .
It sounds that the problems your passion have developed is owing to some incompetent local mechanic's jugaad work on the wiring harness & alternator .
Better to follow shoeb's and others easy instructions and get your hand dirty(I am doing that too now) . Plus points are that the tools and parts are really cheap , easily available and the bike is easy to repair yourself . We have very very helpful and patient people here on this forums to guide you .
If you can't manage that , you have to find a very competent and honest Hero ASC , if there is a such thing . Where are you in kolkata ?

BTW - all genuine parts for HeroHonda bikes are available at Bansal Motors in wellington near Jyothi Cinema Hall. They are the statewide distributors for Hero in WB . Tools are all available on the same street around chandni market .

That a relief.....so they are quoting high, The spare shop quote it comes under 500-700/-.

No I'm not that much advanced user...can't do that...wish I can .

If I remember slightest bit of it , I presume the 2nd one is mine...not sure anyway, Any chance a 3rd kind exists in the market ?

I'll defiantly post the current OIL leaking picture of that engine once I get back to home,

Here I'm going to describe, As if freshly wash the bike the first engine oil appear in the right side lower portion of the engine where the piston block (Hope I name it correct) join with the crack case....no there is no leak from kick start lever as well as Dip stick whole. Then Oil spread slowly (after using each day) all over the engine body Top, Left side,Engine guard plate from the bottom.....This whole process take time 2-3 weeks upon using.

Not sure how this alternator got damaged and why he need to recoil it,but after getting light intensity bump I don't bother to ask him . The mech is reliable one....and I surprise to see he don't have money leeching habit or keep the customer in hand like others in my area .

Anyhow what he did in that time or what I encounter during that time is below,

Engine OIL draining hole is wear out badly due to age of the bike and tremendous amount of Engine OIL leakage was the result, to solve this problem around the hole there need to apply some layer of metal, So he told the bike/engine need to take where the lathe machine is to put some layer or so around the draining hole . (and I don't have any more idea about this matter frankly speaking)
anyhow after doing this the problem solved and it is almost 1 year the leakage from the bottom solved.

Anyhow during that time I asked if he find anything worn out he can replace, and he replace many thing like timing chain (small chain),clutch plate and all most all rubber seal gasket.....and yes the one which is behind the alternator too. As I remember this cause it need to change 2 times due to fitting defect with his helper boy.

During this time he recoil the alternator.

It is 2 week job and I not present there all the time though.

After recoiling the bike loose the battery charging feature.....else there is no problem with lights or other stuff.

Thats all......

The third type of coil is used on newer bikes which is a four hole coil,Cost Rs.320.

DO NOT go to a mechanic to replace the coils as they do not solder the connections properly.
Get the address of a Motorcycle electrician from your nearest battery walla .
Never re-wind the battery coil as it will interfere with ignition charging coil.
(Not a problem on new bikes with 4 poles)

If your passion is 2001/2002 ,it probably has a "Two hole lighting coil"which costs Rs.188.

2 weeks job ??? A good mechanic can overhaul the engine within 2hrs max + 1/2hr to fit it back on motorcycle and check everything.
I think the drain bolt was over-tightened as a result threads got stripped.

.

Yes, my mech done all the jobs by separate person not by himself.....like apply the layer at the bottom by lathe wala who is 10km away, recoiling done by battery wala (who is also a car electrician) who is 2.5km away from his shop plus mange his own shop plus regular customers....so it took 2 weeks.

If I go to spare shop and ask "Two hole lighting coil" will they hand over the coil or I need to quote some specific model number......please reply.

Yes the bike is 2001 Passion 1st generation....below the current pictures of the engine and the oil leaking condition.

2nd pic right side of the engine
3rd Right middle side
4th Right Bottom
5th Left Side
6th Left Bottom side

Those dark/dirty patches are the leaked engine oil which hold the dirt all over the body.

I'm from Barrackpore North 24 Pargonas....not proper Kolkata

There is no good Hero ASC in my locality, 1 is there but it nearly shut down,

Thanks Pinaki Ji for this info, my mech also told me the name but he don't want to reveal actual location of this shop. Thanks for the info.

Anyhow to open the left side crankcase & access the alternator I need a 10 number T-Range I guess, what else do I need ? which shop do I need to visit to buy some tools ? please guide.

Besides the tool kit supplied with bike I have 17 number Ring Range/O Range to drain the engine oil.


I searched a lot for T-Range at Chandni Chawk (Bazer) but can't find one, guess I'm searching at wrong place.

Edit:- one more query, If I go with this bike to Bansal Motors in Welington and show them the bike (if it possible) or ask them about "Two hole lighting coil" as shoeb2015 quoted in previous post will they able to help my purchase to get the exact model ? Please enlighten.....

If so then this is my 1st priority.