Mine is the '97 Splendor .. Yeah and I want to restore it fully. Increased petrol cost makes me want to do it anyway So , How much will it cost? Please guide me through the whole process and cost

To open the magneto cover,you will need-
1.Magneto holder
2.Magneto puller
3. #8 T-socket wrench
4.#14-15 combination BOX wrench

OR
Get it opened by a mechanic for Rs.20 ,take some pictures and post it here so that we(members) can confirm.

From the pictures - Cylinder block-crankcase gasket is leaking(Can be fixed easily)
Cant say whether the crankcase is leaking because the engine is too greasy and soaked in oil.
Please wash the engine with kerosene or diesel and ride it for 10 kms and upload the pictures again.


Do want to do it yourself ?
Check out -

That's ok , but if you don't want to do the work yourself , better find an Hero ASC . Your bike looks fine otherwise . The oil leak is pretty bad ... keep toping up the oil every weekend untill it gets repaired , there is risk of the crankcase oil level going too low and causing engine seize , specially with this current summer heat . It looks like a case of simple gasket failure . Just replacing the faulty gasket will solve it . Original gaskets come for 10-30 Rs at Bansal Motors . Older asbestos type(black) is preferred to the current paper type(green) . The most common mistake local mechanics here do while removing old gasket is to strip it quickly with sharp blade like a hacksaw blade . That causes scratches and grooves in the crankcase's mating surfaces and leaks despite new gasket . Remove the old gasket gently after soaking it with kerosene , with blunt screwdriver or the like . If scratches and grooves are found present , polish off the mating surfaces patiently with fine (800grit or higher) wet emery paper until no imperfections are visible . Coat both sides of new gasket with clean grease prior to installation .
Tools are all available on the same street , that leads to Jyothi Cinema hall on the footpath itself . You have to leave the proper Chandni market and walk towards Jyothi cinema hall, hawkers sell on the left side footpath . Ask any shopkeeper there. You need No.8 socket and T-shaped or L-shaped driver handle to open crankcase sides . There is also better quality tools available at many shops in wellington area like Taparia-tools brand , hardly needed since we don't use/abuse tools like the mechanics . This is the tool , with a parket vector pen beside it for size comparison . You can fit and use socket at both ends , depending upon the force(torque) required . Get no8,no10 & no12 sockets at least .



Unfortunately Bansal Motors is a very professional parts dealer , meaning that they won't take a look at the bike ... they'll just sell parts . But if you ask them for stator-plate-coils assembly and mention the type or model No etc , they'll know what you need at once and pull it out of stock . Asking for Two-hole lighting coil for passion+ year , should do the trick there . Fitting of stator plate, coils etc is quite simple(thanks to shoeb) , but you also have to check if your mechanic have altered any other part of the electricals and wiring and set it right . Buy a new battery too , old one is probably kaput owing to not charging for long time .
Your mechanic did one thing right at least , re-sleeving new threads on a lathe is the correct way to repair stripped drain bolt hole . With excessive forceful tightening(long ring wrenches) can cause fine hairline cracks on the engine case itself, check for very fine lines radiating from the drain bolt hole and around it . If you use right amount of force(less,very much less with No17 long ring wrench) to tighten the drain bolt and a new crush-washer(1 Re) you should not be stripping it again .
Remove the rubber flap(jol guard), engine guard etc at least for the summer .. they hamper air-flow over the engine and overheat it .

Since your splendor has not run much then i am assuming there is no engine work involved. However check if the engine is smoking and get back to me. Now i am providing you information for body and chassis overhaul. After posting about engine i will guide you on engine.
Completely dismantle the bike at your place. Remove the chassis and, you yourself rub down the paint using 320 grit silicon carbide paper. Where rust is present use more coarse paper. If your place has a sand blasting place then take it to there and sand blast it to remove all paints and rust. For this only chassis is required. Remove every thing.
1. Before painting change the swing arm bush as it requires lathe work and will cause scratch.
2. Buy new rims, original spokes, wiring sets, headlight of splendor+ , rear shock absorber, check whether shock inner pipe of front is OK or has scratches near oil seal. If scratch is present change the pipes.
3. Buy each rubber grommets and pipes in the body to new as every part is available. Buy new bolt kit which is available in original pack.
4. Find a good painter and tell him to paint every thing to original color. tell him to use 2k color.
5. If there is no good painter then find in adjacent towns if anybody has paint booth.
6. Else you can buy new tank, panels and rear cowls for Rs. 6000 and give the chassis, drums, engine and chain cover for painting and tell him to paint in 2k paint and original scheme.
7. I will post in my next post what you will need to change and how to maintain stock looks.
Hero Splendor Plus Bike, Splendor Plus Price, Mileage and Specifications ? Hero MotoCorp Ltd.
You see in the site that your style splendor is coming.
From your picture, it looks oil is leaking from bore packing, the packing between bore and crankcase. For this you have to open head, and cylinder.
While you are at this do a partial overhaul.
When you open the bore check by inserting the ring what is the gap in rings. In horizontal engines the gap should be very less.The gap must be such that when viewed against light only a tiny amount of light can pass and the gap shouldn't be visible by looking normally. Only when viewed against light the gap must be visible.
If the ring gap is OK then take the bore to lathe and ask them to lightly hone it so that only the honing marks are visible and no material is removed. Buy new standard size rings and fit. If the ring gap is more then buy oversize rings and ask the lathe guy to grind it according to bore.
You can solve the oil leak without doing the above but doing the above will result in bump in compression as you will be removing the bore any way.
Now for packing, buy bore packing(paper), head o-ring kit (3-pieces), head packing(metal packing), and top cover packing, side cover packing.
Also polish the valve seats and change clutch plates if not done.
1. bore packing- Rs.20, Head packing- Rs.110, Valve oil seal- Rs.60, O-ring kit- Rs.47, Other packing- Rs. 30, Lathe- Rs.50 and Rings- Rs.200 (original), Rs. 360(usha).
2. Clutch plate - makino (Rs.200), Clutch cover packing- Rs. 27, engine oil- Motul 3000 4T (20W 40)- Rs.230.
This is known as half engine overhaul and will restore your bikes performance like the day it came from factory.
Total it will cost you Rs.1500 and since your bike has run for 60k after this it will easily run for another 60k without any major maintenance.
Since you will be opening the bore for changing the packing so i advised you to do the light honing and change the rings other wise if you fit it chances are that the engine will smoke.
Go for new lightning coils. There are three type of coils-
1. Single coil- posted by shoeb.
2. three coil with two mounting holes- posted by shoeb
3. Three coils with three holes- Same as above and has three mounting holes.- this type has been discontinued from splendor onwards and was only available in very old CD 100.
By the type of alternator he meant that is it DENSO brand or NIPPON brand or Other brand which i cannot recall. The stator plate is matched to the magneto and you can find the brand by looking on the magneto. It is stamped on that.
@shoeb- De carbonizing the head does not require the magneto to be removed.

Thank You for correcting me.
(Edited My post)

Are you sure its paper packing ? It was rubber in cd 100 engine.

Yes, this is I'm going to do first, So that I at least know which kind this bike accept, Thanks for the suggestion.

Thank you sir for your nice informative post, I'm great full to you post the tool picture. I note down the necessary tools number..as I'm looking for this for long time.
Anyhow as you said & I agree A new battery is always good,(a little bit history here) but in my case after the overhauling or may I say the big work done last year the bike completely lost the Battery charging capability, so when I first encounter this problem I regularly charge it myself & topping it out with distilled water when needed....(yes this thing I can do by myself). So once a fully charged battery last for 3 weeks with usage (85% drive with Head Lamp On), after that it shows the week horn/break light etc and I recharge.

.....I continue this procedure by myself in regular 3 week interval since the bike lost the charging capability. The output voltage of the 2 terminal shows 12+ volts or something.

And at the beginning of this month (May 2012), I need some small work done to the mech, I gave the battery to professional hands (Exide showrom) they check and said everything is OK and they charge it and return free of cost.
Now I don't want to buy a new one unless I get guarantee the bike able to charge the battery itself.

Now the question if I doing this past 1 year, then why I suddenly need to fix the alternator ? Because I need to move this vehicle 70km away from my home where I'm not able to help to charge the battery every 3 weeks interval. <-----This is the biggest obstacle for me and I want a immediate fix.
So I want to install a new alternator to try before gave up on this bike.

And topping up extra engine oil in certain interval is continuing/done by days when the engine loose the big amount of oil leakage under the draining hole, so engine drying/seizure vulnerability is well covered.

One more thing I like to add, as you wrote,but my bike is not passion plus,but a regular 1st gen passion model....no plus sign in it. So if I ask them to passion plus alternator will they identify which I'm talking or Is it compatible with mine ?

Thanks a lot sibun for this post, to ultimate help /care what this bike actually need, but I don't know If I actually gave it, No budget is not a problem here but finding a proper actual mech or SVC who can/want really help and don't hold the customer in their hand....is hard to find.

first portion of your post is over of my head though....anyhow I only understand the part of spare lists, which this bike may need to cure itself.

I must mention, this bike don't have any problem though be it pick up/light intensity/abnormal fuel consumption/smoke from the exhaust or any thing.
very rare 1 or 2 misfire though occasionally.

My not so sophisticated mech change everything in clutch plate section as I guarantee (in fornt my eyes) i,e the clutch rings and the bowl type holder which holds those rings.

This bike don't have any problem except two, i,e battery charging and oil leakage (If I count this ).

Anyhow I noted down all the spare you mentioned and going to ask him if changed this stuff in that period or If I change now is it going to help any.

I also want to know (If it possible to quote), How much do I need to spend, If I gave my bike to a HM's SVC to sort out all this problem, any idea ?

I am referring to the packing between bore and crankcase. It consist of an o-ring in the oil return path and a paper packing and i am 100% sure about it.

If your clutch is overhauled then leave it. Your oil leak is between bore and crank case and you have to remove the bore for it.Since your bike has run for 60k if you fit the same rings and bore then your bike will smoke. Do not take to service center as they will just change the bore and charge you. Just take the bore to a reputed lathe work shop and tell him to hone it lightly so that only the criss cross pattern is etched without any removal of material. He will understand it.Now ask him to insert the rings and check if it is OK. If not then buy a oversize rings from spares shop and tell the lathe to do the needful. If the old rings are OK then buy a new standard ring and refit it with honed cylinder Wait for two days i will post a photo of the detail.

But in my cd 100 engine it was a black colored gasket and was at-least 3 mm thick.
I think it was asbestos

The problem is to find a competent lathe operator or independent mechanic for this work, here it is a rare species . Still if neel may find one , then this is the best solution . If not, then he has to approach an Hero ASC . Atleast they have the proper tools, facility, training and genuine parts .

I know what it takes to find a good mechanic. But i posted it so that he can know what works are to be done and if he gets it done then he can personally check the points that i have mentioned.

A fellow member(Above_All) who has a passion 2002 model had a two hole coil.

Here is my Alternator of my bike,just came back from the mech after clicking, please let me know what is the modle name.....I can upload those pic in other image service to view the full res if this is not enough.

Shot is in Nokia N82....thats all digital cam currently I have access.

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My mech said I don't need to change the yellow thingy which help to start the bike, I just only need to change the 3 coil portion as I don't have any starting problem....but I can/want the whole assembly change if you guys suggest. 10+ years more than enough for me.

Just let me know what I need to say the parts distributer....they are big shop/distributing channel for West Bengal & most probably they don't bother to entertain the noob's customer foolishness. please help.
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Edit: Here is the image shack link...can be viewed in full res version.

It is called "4 Hole Lighting coil".Tell the shopkeeper that you want a "Hero Honda 4 Hole Lighting coil"

No need to change or fiddle with the "yellow ignition charging coil".If your mechanic tinkers with it, your bike wont start.

Thank you shoeb2015 for your instant confirmation......So I just need to say
"Hero Honda 4 Hole Lighting coil"

If I need to mention the bike model name...or I guess all HH model got the same stuff.

Thanks a lot.....I'll be go to pickup that stuff at afternoon.
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Edit (Update):- Took those picture on 7" Tablet and rush to the Bansol Motors,Kolkata. First asked them about "4 Hole Lighting Coil" for Hero Honda Passion as fellow member shoeb2015 mentioned they just refuse and within a sec I show them those photo on 7" tab which is stunning and clear (Everyone take a look at them who are present there incl other shop employees), then a guy approach with statement " We don't sale you anything unless you bring the sample or part number collected from Hero Showroom".....I completely failed to acquirer this product today. Return home frustrated......

On the way back home I visit to the nearest showroom where this bike actually bought (by hoping to get the part number) as it came to EOL as the pounding sale of neighbour Yamaha showroom, they 1st don't want to entertain (that I'm not even there) but once I pull back my Tablet they suddenly show some interest on me. I asked them please give me the part number, they pull back old Original HH Passion WorkShop Manual (The picture of my bike is in the front of the cover,a Silver one) and suddenly changed his word....."By seeing your picture we believe we have those in stock,but we don't give it to you...but we can install it for you in your bike,the complete charge is in between 1000/- to 1500/- you can expect. But we don't guarantee it will solve your problem of Battery charging...you leave the bike for 2 days." Plus he add "we don't disclose the part number to a customer....this Company - Delar corporate privacy privilege".

I thanked them and promise I'll give my bike next week.....which I don't of course.

This the chance I get to give this bike a complete overhauling.....hmmmm.......

Usually that is the case with electrical/electronic spare parts everywhere because
1.You may return the part back or ask for an exchange so they(shopkeeper)always insist you to bring the faulty part.
2.They don't know the exact name or don't understand what you say.
3.Many of them are illiterate(shopkeeper assistants) and identify the part only by looking at the faulty part to be replaced.

Replacing your coil will fix your battery charging issue 100%.
Why?
Because I also faced a similar problem when I re-winded the battery charging pole of the generator.The stock coil has less no.of turns on battery charging pole for a particular reason.(I will explain if anyone wants to know)

@ Sibun
What is the cost of stator plate with ignition charging coil,lighting coil and pickup coil ?
I thing it should be less than Rs.700/-.

@ NEEL
If you feel that you cannot find the coil or a good electrician to fix it and If budget is not a problem then replace the entire stator plate.