Are you still filling it with the HeroHonda 10w30 OEM oil Gansan'jee ?

Why compromise on performance and mileage, just get a new OEM cylinder kit and recondition the carb, and the bike'd run like new for decades to come i.e if the clutch plates etc are in shape.

Hmm...actually the recommended oil in the manual is Servo 20W/40 and that was her diet for the first few services. Then they introduced this Hero Honda 4T+ oil which is 10W30 at the A.S.S all over India, and she changed to that sometime in late 2000. Recently I changed it back to Shell Advance 20W40 to see if there will be a little less leakage, but to no avail. So it is back to the OEM oil now.

I actually feel that had I continued with Servo, my engine's life would have been more.

Just a top-end overhaul will solve your problem.
Get the head re-conditioned at a lathe.
Remove the camshaft and inspect it.
Replace valves and valve guides to prevent oil leaking into cylinder.
Remove and inspect rocker arms for wear marks.
Replace timing chain and guides.

Replace the bore and piston (USHA make).
Replace cylinder head metal gasket,cylinder-case gasket,tappet cover o-ring,rocker cover gasket.

Clean the centrifugal oil filter,strainer.
Replace the clutch and steel pressure plates.
Replace clutch Springs.
Replace clutch cover gasket.

Clean the pcv vent tube by blowing compressed air.
Clean and tune the carburetor.

Total cost <Rs.5000/-

^^I am not that mechanically inclined! My DIY on my bikes are limited to washing and cleaning, oiling the chain and other points, and cleaning/oiling the air filter once in between services. It is about the same on my car as well, with one difference! I don't bother to clean the paper air filter: I just fit a new one every six months and throw the old one away!

I have full trust on the foreman at the A.S.S, he is a friend from my school days - a school mate, actually.

Moreover, if parts need to be changed, I will prefer to change the entire set and not retain anything old.

Do not go for re-bore as the lathe guy do not use good tools for the job.
Even if you buy a new bike then also recondition the splendor as it requires only few thousands.And one thing i want to warn you about that OE parts doesn't mean best quality. Gone are those days when OE parts were of good quality. Now some after-market manufacturers produce much better parts. If you are interested to know then please post here.I have experience of overhauling almost every engine and my joy i have overhauled nearly three times. So if you want to make the bike as good as it came from factory then post here and i will guide you.
@pinaki- You are right even i find that hero bikes are of much better quality than any other manufacturers. I have Four hero bikes(pleasure,joy,cbz extreme, splendor+) and i have seen they are of much better quality than other bikes. Even honda doesn't provide such quality.
@shoeb- I didn't mean to hurt you. You thought i was irritated of your curiosity.There is no inconvenience caused and instead i am glad you show curiosity in all. Instead i scold my younger cousin brothers because they have no interest in any thing except eating and watching TV. I feel that this is the case with all our younger generation. They don't have the interest like us.
I will tell you a real incident that happened with me. When i was studying in Std. VI one bachelor uncle use to stay as a tenant in our house. At that time we had a bajaj scooter(Joy was bought when i was in Std. VII) and our uncle had a bottle green suzuki samurai which he maintained in immaculate condition. It was my first crush in bikes and still i am in look out for a decent samurai.
So the uncle on seeing my curiosity use to tell me all about the bike and also take me along for servicing. Samurai being a 2-stroke bike required head DE-carbonization at every 3k and it was also quite easy job as it doesn't have any parts in head.I saw it and in my mind i decided to do it. Once when i was alone i quietly opened the head and cleaned it and set the gasket using dendrite. Uncle when rode it was surprised that the bike felt smoother and felt quicker. After 5 days i told him and he was glad but also told me to do all that when he was present. So i need to tell is that curiosity is good and we shouldn't discourage it.
I have prepared all the photos and will post in next post as i require one complete post to explain it.
Ps- I still have a crush on the samurai but it was stopped before i could buy and i am on the look out for a good second hand.

Off Topic

@Sibun
The happiness in doing DIY is priceless.

Curiosity to "learn how stuff works and finding out whats inside it" is there right from my childhood and this curiosity keeps on pushing me to learn more and more.My parents encourage me and continue to do so.

You are right even my younger brother shows no interest in all these things.

If possible can you zip the pictures and upload it to 4shared.com ?

Splendor Clutch replacement.

Today evening I had opened clutch cover to clean the centrifugal filter but I thought why not replace the clutch plates so I replaced friction and pressure plates because my kick was also slipping when kick-started in morning .


Here is the list of items I replaced.

Makino clutch plates -Rs.120/- (Original costs 320)
Original Pressure plates -Rs.75/-
Springs -Rs.20/-
Clutch cover gasket/packing -Rs.30/-
Kick oil-seal -Rs.14/-
ANL front brake shoe -Rs.90/-
I did not change oil because I had changed it just three days ago.

It took me about an hour to replace it because I even had to remove the silencer to loosen the RH foot peg bolt.
I borrowed that "special rotor nut tool" from my friend.

The engine was super clean,centrifugal filter was looking brand new ,strainer mesh was also clean .
Maybe because it has seen more oil changes than what is required ?
I change oil every four months irrespective of kms covered.

I am NOT going for a re-bore! That word is allergic to me! Please let me know of these after market parts. I will not be able to do it myself, but can catch hold of a mechanic who will act as my hands!

(Pic taken from Mr. Pinaki)

I have removed the rubber small air flow pipe situated in the upper right corner of the airbox (shown in red circle) for better air flow keeping the stock air filter intact. Can i get minute increase in performance and will this affect the engine. My bike clocked 154032 km and I am getting mileage around 67-69 km/ltr and it can touch around 91 kmph. Thank you.

Poll..

Congratulations to owners of world's largest seller !!

Please quote your max. speed attended on Splendor....I do know it's not a speed m/c....but I have seen a splendor overtaking my swift when my car was at 95 kmph...and that too with pillion !!!

If you remove the snorkel, then theres a chance than water may enter during heavy rains, my friend removed it on his Hunk and there was a noticeable change in the intake note, cant commend on performance though. And you can expect an increase in mileage, since the AFR will be abit lean after you remove it.

Pics please .

You can experiment with it ... no harm to engine, but don't use the bike like this in monsoon(or during a water wash) ; that snorkel is essential to keep water out of the air-filter box .
Mine is running 60-61 kmpl only in summer because my run is low and irregular now (because of the heat) and evaporation loss is considerable in these sunny days . I used just a liter this last week .Yours is one of the earlier splendors , the best ones ... before they had to tinker with the engine to meet the BS pollution norms . Haven't tried this bike above 70kmph yet , mainly because I use it for local runabouts and office going (sometimes) and I am scared to take any bike above 70 nowadays on kolkata roads ... too risky .

Many think that splendor series engine are worst in performance. many have not seen the performance and still they give their opinion that it doesn't perform good.
i haven't tested splendor top speed but has touched 90 kmph with ease.
mine is hero honda joy(2001) which although has same series engine as splendor has slightly more power and torque. so it has a 42 teeth rear sprocket and thicker tyre.splendor has 43 teeth rear sprocket. my bike easily touches 110 kph even when it has run 3.1 lacs km. with 2 up it touches 105 kph. so a splendor can touch 100 with single or double. my joy has touched 110 more than 30 times and almost once in a week touches 95-100 while going to work.
i also own a cbz extreme and i know it can breach the 120 mark easily but till now i haven't seen any bike which has so good performance as splendor series(joy,splendor,passion,e.t.c) .
on NH i have surprised some of the 125cc guys with my joy and 2 riders on next traffic stop have asked if it is some new 125 from hero honda because 99.9% haven't heard of joy and i maintain my bike in such a way that it looks like it just came from showroom. so a splendor crossing your swift at 95 kph is no surprise feat.
some day i will try to post a video if i will be able to shoot.