as I am from Jamshedpur I have to see the prices here and is the new cd dawns light good for Night highway rides or not if you can advice.
Thanks

a total cost of Rs 19,000 like that ,as seen on one of the post by sibun will my bike light will increase drastically.DO you ride your crux bike more often on highways,As I travel in highways here I seem to get a disbalancing and vibration (on like my fingers after say 30 km ride feel vibration in my fingers bone and also rings on finger) handle while ridning at 50-60 or above KMPH constant. So I want to know how to myself check the alignment issues of the bike on tyres, body struture, shock absorbers etc without going to service station ,As reading all of you's technical work I want to leanr also.
Thanks,

dont think for spending 19000 better buy a new bike instead...
My bike was also having a lot of vibration too...but dont know how it was gone now.....as i remember it was its engine fault..because i also tried many things before to get rid of vibration but the vibration only gone when my engine was firstly bored.

To check if the cause of vibration is engine,speed up to 60 kmph and switch of the engine or Pull the clutch and coast down.
This way you will get to know the source of vibrations.

I don't have any kind of emotional attachment with this bike because others drive it more than me,unlike my splendor which I plan to keep it forever because there are many memories attached with it and it has never fallen upon me even during toughest of times.

Yeah , me too .. since kid bro is riding the cbz-x I have almost stopped taking it out . Moreover he doesn't maintain it the way I like .. I hate riding dirty bikes , even if it's raining . No one gets to ride my Splendor ever . I have been quite rude in denying borrow requests from friends and neighbors .. and believe me Splendors get more requests like that than the others . They can take the old max100 if they want . Strangely enough whenever a friend has returned a bike after borrowing it felt different-to-ride to me ...

I no longer have any of these bikes and since a long time too ... I'd need a whole garage to store this many . Roadking's engine sound got constant complaint from neighbours particularly in those days I'd have to rise very early and take off .. and you wanna hear that ? It was given to a girlfriend's kid bro . Bajaj super was kinda taken away by the same guy who came to my place monthly to service it . Foolishly sold off the nv and looking for a working one now .. it was a damn good scooter ... as good as dad's Vespa150 on whose footboard i'd ride(stand) a lot as a kid ... and will never forget that fun . These days it is painful to see they are just cutting up old working scooters into scrap metal here .

Finally this post is up and i will post how to change the bore piston kit so that the performance of your bike is good.
First let me come to my problem which prompted me to open the bore.
The problem were as follows:-
1. From February this year the mileage suddenly decreased to 68 k pl from 78 k pl and no amount of servicing would increase the mileage.
2. On DE-acceleration there was a slight ringing noise which indicated that the rings were not sitting properly and was vibrating in their grooves.
3. Just two months ago the engine was opened and con-rod was replaced but bore was good so was only honed but we made the mistake of not changing the rings.
4. The engine was loosing compression once hot and the tuning was rising to 2000 rpm when hot.
5. Valve leakage was not detected as the engine was not showing any problem when cold and the kick was also tight indicating valve seating is correct.
6. During last few days the mileage decreased to 55 kpl.
So here are the the procedure.
For opening the head follow the following procedure:-
1. Open the right side panel and open the nut holding the rear footrest bracket.
2. open the center nut which is holding the silencer. do not force the silencer to open.
3. open the two silencer nut from the silencer mouth located at bottom of head.Now remove the silencer.
4. open the carburettor cover(black cover under the tank) and remove the bolt holding the intake manifold to carburettor.
5. Open the gear lever and magnet cover.
6. Open the air injection unit.
7. Open the timing cover and match the timing by placing the magnet T mark against the casing mark and also seeing the mark on the timing sprocket matches with the head mark. Now open the two small nut on the timing sprocket and remove the sprocket.
Now open the small bolt holding the head at the side just besides the timing cap and then open the 4 head bolts in crisscross pattern. Remember always open the side bolt first and then the top bolts.

Many confusion are there on xbhp on tuning of carburettor. See the tuning from the spark plug-

The timing mark matched to mark on engine casing:-

The head bolt removed and the intake manifold removed from carburettor-



You can see the carbon deposits in the above picture.The o-ring present in the oil return gallery is responsible for stopping engine oil from entering combustion chamber. If it gets damaged the bike will smoke like 2 strokes.

The picture is self explanatory. You can check the exhaust valve by opening the spark plug and focus torch through the hole. Now slowly rotate the engine by shifting the gear to first and moving the rear wheel on main stand. You will not have any difficulty as there is no spark plug so the compression is nil. After rotating for about half rotation you will see the exhaust valve will rise. Now look it in torch light and you can see the color.If the valve is red then there is nothing to worry as tuning is correct and petrol is also of good quality.

The old bore was worn at one side. So it took the shape of an oval and thus the rings were floating without touching the bore at on side and touching other three side. The ring gap was 0.5 mm and was same for top, middle and bottom. The problem was not with gap but with bore being outof round.

We were inserting the piston and ring to check the ovality of bore but my mechanic came and just gave a look to bore and told exactly where the bore has worn. Now you know what 20 years of experience mean.The bore was worn in this way because the clutch side of the crank-pin was worn and thus the con-rod was giving more thrust to that side.

The splendor and joy piston are placed. Joy piston has larger skirt and also landing for absorbing thrust of combustion force. You can fit the joy piston in splendor but cannot do the reverse as it will cause rapid bore wear and rattling of piston in bore.

The DID timing chain which cost Rs.174 and the OE chain cost Rs.100. If you cannot find DID then go for Rolon or Diamond but do not go for OE.


This the USHA bore kit.
Why i went for USHA bore kit?
The first time i went for engine rebuilt was at 1.24 lacs km. At that time i bought a OE kit which had USHA liner and piston. The bore kit ran for another 1.20 lacs Km and while opening there was no smoke and the bike was returning a mileage of 70 kpl. During the tenure of this bore The bike sometimes used to return 100 kpl on NH and also touched 110 Kph effortlessly. AT 2.44 lacs another engine overhaul was done and OE bore kit was used but it had piston of SAL. The bike started consuming oil with new piston and when the head was opened after 1000 km at first service the combustion chamber was full of oil. Then again oversize ring was ground and fitted.The bike ran for 20k and seized. Then the bore was bored and MAHLE piston was used. That ASS**** made the clearance so less that when heated the engine will not idle as the piston was expanding and jamming the bore.The bore lasted for 30k and this time i decided USHA bore as i had previous experience with USHA and also the piston is semi-forged and silicon mixed so it resist thermal expansion.



The valve are lapped using hand. I never go for machine lapping as in lathe and instead lap with hand which gives superior results.

The USHA bore liner is so smoothly polished that there is no risk of seizure. Moreover you can see the liner mark is not there as in OE bore and it is seamlessly fixed with the casting thus allowing better heat transfer.

The usha piston is made in honda foundry, Japan.The rings are supplied by Riken, Japan. The OE piston set cost only Rs.450 but USHA piston set cost Rs. 750. So you can imagine the quality difference.






Difference after bore fitting:-
Since we regularly use our bike we do not notice how much gradually the performance is decreasing.
After fitting the bore the low end torque has increased and the bike is eager to pull wheelies. IN my joy the low end torque is so good that even if the engine will be idling at 1000 rpm if you slowly release the clutch in first gear it will pull without touching the accelerator. This was missing which gained after bore was changed.
Difference in USHA bore-
Even though the ring gap is so less and the piston is tight then also the bike feels free unlike in OE kit where we have to run it for freeing the engine.