No No,not that yellow thingy.
The entire plate needs to be replaced.
All the coils are attached to a plate and it is called stator plate.
It will cost around Rs.700/-.

Do not connect the horn to Ac.
Do not do any alteration,instead of making it a trouble free machine it will become a troubling machine.

EDIT:
Four Hole Stator coils is available(Non OE) and is made by another manufacturer SWISS which is a reputed company.

so if the 4 hole lighting coil not available, I need to change following, please confirm; (if possible please quote the price also)

So,

1.stator plate = 700/-

2.two hole lighting coil = ?? /-

3.Yellow cylinder thingy = ?? /-

Anything else please mention...the rubber gasket/washer,E.oil available locally...no problem for those.

To Sibun, If you reading the just above stuff, can you please able to mention the part no of those following item ?

If anyone can able to provide the part no....collecting those stuff from distributer channel in kolkata is very easy task for me else...

All those parts are already fixed to the stator plate,no need to buy it separately.

@Sibun
It would be great if If you could find a parts catalogue.(I searched all the shops here,no luck)

What is the reason for shortage of spare parts ? Hero-Honda split ?

@Neel-Do not worry. i will post the part number by tommorow morning may by today night. your coil is of JHI company and different company have different cdi charging and pickup coil combination so use the magnet of same combination. if original is not available then use swiss as shoeb mentioned. it same quality as oem.
@shoeb- there is no shortage of parts. its only that prices of all are increasing by 20% so artificial shortagd of parts. parts catalouge they will not give you and ihave it with my retailer friend. do not worry i will post it after my scanner is repaired.

@Sibun
Yes,there is some judder while releasing the clutch only when the engine is hot.
When it is cool there is no judder.

How to check the clutch housing for play ?


I went through previous pages and I also want to decarbonize the cylinder head because my engine is feeling very rough and overheats.
Also read shoeb's post on how to decarbonize head.
Is that ok ? Shall I decarbonize it ?

I have done a lot of work on my cars and I have a lot of tools so I want to try doing it myself over a weekend.
What do you say ?

(It feels great to have like minded people having same passion and interest here on xbhp)

Bhai Neel , no need to worry so much .. just get a new stator plate as suggested and start the work from there . It's not so complicated .
Be patient when you go hunting for parts .. you'll get all parts in Wellington area; Splendor/Passion/CD is still the number one sold bike in India and possibly the world . No problem with parts supply . I suggest that you try Bansal motors shop once again , all the HeroHonda ASCs collect long lists and bags of parts from there daily .. so maybe if you approach at a better time and with more patience , they'll be helpful .

No, no shortage here in Kolkata . I am able to get all that's needed . Shortage here is only of skilled+honest mechanics .

Right . Price have suddenly increased .
Sibun'Jee , we shall be forever grateful for a full pdf copy of that parts catalogue .

Since you did not mention your experience level earlier , I was apprehensive whether you can do it yourself or not . But since you have already worked on engines and have most of the common tools already , go right ahead ... this is a very simple engine, parts are plentiful and cheap . Moreover, yes .. so many knowledgeable & helpful splendor owners here to help has build my confidence too . I have reasoned it like this - now how badly can I mess up this simplest engine in the world - and if I do manage to do that , I can always push it down to the nearby HeroHonda ASC and get it fixed for a few bucks . Not much to lose and lots to be learned . For me , there isn't a better way to spend weekends .

Finally able to procure the system





As my mech can't able to detach the lighting coil from the plate, it got cracked near the black plastic mount (charger.. according to Bansal motors ), So I opt for the whole system.

Here my cracked old one



About Basal motors :-
When they hand over the product to the customer they completely wiped the price as well as Part No.
Every spare they sold they doing this, mine took 45 min of waiting.

Anyhow I first ask give me stator plate of Passion = no result, Please come back with part no.

then I asked Passion Armature plate (This told by my mech)= No result,Please come back with part no.

Then I show them the dismantle sample = Worked .

here the torn down sticker of the box



One interesting thing revealed by my mech later in evening when I'm there to install the whole stuff i,e Bansal Motors Do Sale Spare Part No. Catalogue along with Spare Price Catalogue for all HH Bike....and my bike which is Passion a.k.a Passion Pro cost around 80/- each (price may increase to 100 to 150 bucks). .....I think this is a must have for all DIY people here.

Anyway I want to thank all people here for their continus support.

And yes the battery is getting charged up just 1 km drive (thanks shoeb2015...you are absolutely right) , now all Indicator + Horn + Head Lamp functional without any weakness at the same time.

@neel-at last your problem is solved.today itself i had posted the part number alongwith other members query. but after typing for 30 mins my broadband connection got disconnected.so i couldn't post the reply. it is good that your problem is cured for once and all. presently posting from my phone so i will post others query as soon my broadband is restored.
@all- always think before you do any modification otherwise like neel you will also face many problem. if you feel any doubt then please ask me. not only splendor but any bike, i will help you.

Well done !

My guess is that they have a large stock which they got at the older price and sticker showing that price . Now that Hero-Honda has declared new(10-20% increased) prices , they are selling off their old stock at the new prices and making unscrupulous profit . But since the sticker still shows the older mrp and they know they are violating the S&E ACT and VAT etc rules , they are obliterating the sticker to avoid legal action . Also since they are aware that they are in violation of the law , and can be caught any time ; they are now nervous to sell to unknown customers . The common method used by Sales-Tax etc departments to nab such violators , is to pretend to be a dumb customer and buy an item and get reciept etc, just then the whole team moves in and nabs the shopkeeper redhanded .
Similarly the new price-list & catalog will show the date from which it becomes applicable , and the product sticker contains the packaging date , so matching the part-number to the older HeroHonda price list shall immediately give away their game . That's why they are rubbing off part-number too .

Ohh that would be great ! Did you really confirm it at Bansal that they are selling these catalogs, or just heard from your mechanic ? Please confirm , or else pass me the Phone number of Bansal (i've misplaced it) .. then I'll go buy it this weekend only .

That's great , We're really happy that you finally got rid of the problem . Happy riding .

@Neel
At last your problem is solved..How much did that whole assembly cost you ? Why did you get four hole stator plate ?
How did the stator plate crack ?

@Pinak ji/neel
Can anyone of you get that spare parts catalog and courier me ?(I will deposit the money)

No, they will never give the spares catalouge so easily. I had inquired it in many showrooms but they tell that it is not allowed by the company.
Since my friend is a retailer he has the spares catalouge so i got it from him and i will post it as soon as my scanner comes from service.
@pinaki- can you tell me how to convert scanned images into PDF.
@shoeb- If i post the pictures of my engine works in picasa then how can i make it visible here.I will post the special tool along with the work pictures.

@MSU- Judder at hot engine indicates that your clutch plate is ok but your pressure plate is burnt and there is play in clutch housing. But your clutch plate will run for another 10k easily. so at that time change the pressure plate. You can check the play by holding the clutch housing with both hands and give a sudden twist to the clutch gear and housing in opposite direction with both hands. if there is play then your housing is problematic and you can go to lathe and change the bushes, will cost you Rs.250 or change to new housing, will cost you Rs. 1061. While changing clutch plates change to makino as it cost only Rs.180 and last as long as original.
since neel has already changed the parts but i will post the number for the benefit of others.
There are three suppliers of coil base to hero honda. They are JHI, IN(NIPPON), ND(DENSO). You can find the brand of yours as it is etched on the magnet.
Light coil part number:-
31122 - KCC -900(JHI)- SINGLE POLE 2 HOLE.
31122 - KCC - 901(IN)- 3 POLE 4 HOLE.
31122 - KCC - 905(ND)- 3 POLE 2 HOLE.

Complete magnet and stator assembly:-
31120 - KCC -900(JHI)
31120 - KCC - 901(IN)
31120 - KCC - 905(ND)

resistor part no-
35400 KCC 940

This is said by mech,didn't confirm with Bansal motors....here are their phone number;(as printed in the bill)

Bansal Motors Corporation
Mob:9331307817, Ph:3259 7232 / 2265 3958

It is spare parts catalogue not the workshop manual which I guess prohibited from public.

And Bansal motors spare parts distributer channel for HH not ASC or Show room.
Anyhow my mech said that this can be collected from Bansal itself, then I asked if they refuse to sell, he said it can be arrange from a retailer spare shop solely for HH (where me/he bought stuff time to time) who is the friends of my mech (just like yours) who operate his business in my locality by completely depending on the Bansal Motors.

Just need to go there pay him 80/- in full and he will bring the Spare sparts catalogue (for passion pro) from the Bansal when he next go for collecting his stock(takes time month or so). As I don't need the price catalogue, if need then another 80/-.....thats all. (No bribe involvement)

Price may up or down.

Thats all....

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

Anyhow the phone number is here, any of you guys call the Bansal motors and ask if they will sell the Spare Parts Catalogue for your respective bike.

IMHO Price catalogue is useless it may up or down for time being.

please don't ask if they sell it to a individual/customer....then they became so.....god knows what ?

Upload all the pictures in Picasa album and make sure the visibility is set to "public".
For more info check the thread below.(Picasa's UI has changed but still you can get an idea.)*


OR post the link of the album.This way we can access the original pictures easily.


Below is the link (image to pdf converter)
Image to PDF Converter Free - CNET Download.com



Waiting for pictures.

Most flatbed scanners available in the market come with a free software CD ( like HP Scanjet scanners etc ) for windows . The scanner software contains an option to save the scanned page/documents in PDF format directly (instead of jpg image etc) . Use this as it's the easiest method . Scan pages directly into one single PDF file with the scanner software . If you get scanning done from a shop , they know how , just tell them you want pdf . Linux scanning software like SANE , xSANE etc have option to save into pdf by default too .

For posting pics i) Make a picasa account for free, if you already have gmail/google/youtube/gtalk account , same mail-id/password will open your picasa automatically without making new account as picasa is from Google only . ii) downsize your pic to 480x360(approx) with photoshop or gimp iii) upload to your picasa album iv) login to picasa anytime and open the image , right click and select "copy image location" v) here on xbhp while posting click the "insert image" icon on top of the message box and paste the link to your picasa image in the pop-up box that appears .

Yes, Bansal Motors is the HeroHonda authorised parts distributor for the entire state of West-Bengal . I understand that HeroHonda has one such authorised parts stockist for every state, to whom they send all their items . All authorised HeroHonda showroom/ASCs/workshops are supposed collect their parts requirement from Bansal only . HeroHonda does not supply them parts directly , unless it is an warranty replacement item . Going by this logic they may have both parts and workshop etc books . Very silly of me that it had not occured to me earlier .
Thanks , shall call them up tomorrow and confirm . The number given on HeroHonda website doesn't work(checked long time ago) and I already told you probably why they have become nervous to sell to individual customer ;-) .

Sorry for late replies , will take and post your gulf oil label pic this weekend . Very busy now and coming home too late and tired which you can guess from this post I'm making at 2:27am . Just back home .

Called up bansal motors today morning at office hours on landline pretending to be an HH ASC . They have all the manuals , but they won't sell to me because they asked me to call up the owners rakesh bansal or mukesh bansal directly and even gave me their numbers . Apparently you have to familiar with these two to get it .
Next I'll approach the shop in person and try to plead these two guys(doubtful) .
In the meantime bhai Neel can you place orders (with the advance) with your mechanic or his shop for the 2 most vital Splendor/Splendor+ manuals - i) parts catalog and ii) workshop manual . I'll pay you twice the cost anytime you want . Just get it please .