ZMA Higher Altitude Issue - Solution - xBhp.com : The Global Indian Biking Community

Rockkyyy · 09-16-2009, 10:09 PM

Most of you here are aware of the Issue with the ZMA having issues while climbing up altitudes. This is what I had faced during the Led ride and how it got fixed. Thought it will be helpful for those who are getting Lehed.

The bike generally had loss of power like any other indian bike faces over there. We had 2 ZMA's and a 220Fi. 220 did not had any problems other than the normal loss of power which I think is due to lesser oxygen over there.

Usually when we ride on hills what we do is rev hard in each gear and move one. So when I did the same what was happening is bike was jerking as when the petrol gets over , same kind of feeling. But when I kept the rpm a bit low bike was moving well but not with the expected torque / speed. This issue was there only when we climp up, While you decent no issues. Aslo on plains even if you are at a higer altitude this problem was not there.

I could get this fixed only at LEH so had to live with it from Manali onwards.
We went a mech in Airport road in LEH and explained him the problem and he uderstood what I was saying immediatly.

He knew what to do fixed it pretty quick. Like he knows what he was doing. Later we rode to M Top and K top and did not face any issues of jerk as I was experincing before. I could rev hard in each gear and bike was performing well.

To Fix Follow these steps.

Remove the carburetor

Remove this yellow color screw , the bigger one (Main Jet ?

)

Remove it and kept it aside.. see the narrow arrows marked

Now this is what you have to do. Take an electrical wire remove the external quoting. Use the copper wires to put it inside the jet and tie it.
According to mech bike was getting more pertol than required. So what he has done is reduce the size of the hole in the jet by keeping a wire inside it. That way wire restricts the petrol flow and less petrol pass in.

Now put this back in the carb and carb back on bike - You are done. No more breathing issue for the bike at mountains.

These pics are taken when I was back in bangalore and while I removed it. Back here before removing this the bike was not pulling well in lower gears. While I rev hard it was doing good.

I hope this helps for other bikes too if they face similar issues. Mech said In LEH he does it for most of the bikes.

Now my suggestion for those who are heading there is to get this fixed from manali itseld for a smooth ride. [Specially for ZMA]. Now since u know how simple is the fix please get it done from manali itslef. The mech charged 80rs for this nice job.

Aryan · 09-16-2009, 10:36 PM

Topic Approved.

Good work Rockyyy. Thanks for sharing.

Akshay Jain · 09-16-2009, 10:59 PM

yeah .....thats a very good sharing from you ....thanks and yeah on leh airport road there are lots of mechanic and spare parts shop

Akshay. · 09-17-2009, 04:54 AM

A simpler solution is to remove the snorkel or get a K&N,that makes up for the lack of air.

I have never ever faced powerloss on my Zma at 12000Ft+ altitudes.
mine runs on a K&N RC-1060 with 140 main jet.

Technician · 09-17-2009, 10:05 AM

The above method of putting a copper wire is also a jugaad to make a smaller main jet out of a bigger jet. If you insert the wire while calculating the size of the wire precisely, you end up making a smaller jet and can use it anywhere.

I have been using one of this jugaad in my CBZ in plains for many months. No problem, no extra heating, safety for valves, etc. I tried to make a jet No. 109 out of ZMA main jet No. 125 in this way. I am satisfied with the results.

rachitkohli · 09-17-2009, 10:19 AM

Hey thnkx Rockky.. that was the exact info everybody around must be looking for who have been or are going to head mountains..!

Even I faced this problem, the bike use to give jerks as if no petrol while climbing. I kept the RPM within 3-4k so I didnt faced much problem due to it, yes its true, you wont get that much torque as required. But fixing up the throttle within range of 3-4k while climbing up should not be an issue. Due to getting freezed it was damn difficult to hold on. This solution seems to be really wonderful & next time will certainly give a try when my luck takes me to LEH

jd666 · 09-17-2009, 10:41 AM

interesting indian ingenuity !!! good share!!

aarunn · 09-20-2009, 04:58 AM

A great Piece of info..... Hats off da

moeed · 09-20-2009, 02:08 PM

Nice info there! Thanks for sharing!

karthik_k · 09-26-2009, 10:41 PM

thanks for the share mate...great info

09-16-2009, 10:09 PM	#1 (permalink)
Rockkyyy Senior Member Join Date: Jan 2006 Location: Dallas Posts: 581	ZMA Higher Altitude Issue - Solution Most of you here are aware of the Issue with the ZMA having issues while climbing up altitudes. This is what I had faced during the Led ride and how it got fixed. Thought it will be helpful for those who are getting Lehed. The bike generally had loss of power like any other indian bike faces over there. We had 2 ZMA's and a 220Fi. 220 did not had any problems other than the normal loss of power which I think is due to lesser oxygen over there. Usually when we ride on hills what we do is rev hard in each gear and move one. So when I did the same what was happening is bike was jerking as when the petrol gets over , same kind of feeling. But when I kept the rpm a bit low bike was moving well but not with the expected torque / speed. This issue was there only when we climp up, While you decent no issues. Aslo on plains even if you are at a higer altitude this problem was not there. I could get this fixed only at LEH so had to live with it from Manali onwards. We went a mech in Airport road in LEH and explained him the problem and he uderstood what I was saying immediatly. He knew what to do fixed it pretty quick. Like he knows what he was doing. Later we rode to M Top and K top and did not face any issues of jerk as I was experincing before. I could rev hard in each gear and bike was performing well. To Fix Follow these steps. Remove the carburetor Remove this yellow color screw , the bigger one (Main Jet ? ) Remove it and kept it aside.. see the narrow arrows marked Now this is what you have to do. Take an electrical wire remove the external quoting. Use the copper wires to put it inside the jet and tie it. According to mech bike was getting more pertol than required. So what he has done is reduce the size of the hole in the jet by keeping a wire inside it. That way wire restricts the petrol flow and less petrol pass in. Now put this back in the carb and carb back on bike - You are done. No more breathing issue for the bike at mountains. These pics are taken when I was back in bangalore and while I removed it. Back here before removing this the bike was not pulling well in lower gears. While I rev hard it was doing good. I hope this helps for other bikes too if they face similar issues. Mech said In LEH he does it for most of the bikes. Now my suggestion for those who are heading there is to get this fixed from manali itseld for a smooth ride. [Specially for ZMA]. Now since u know how simple is the fix please get it done from manali itslef. The mech charged 80rs for this nice job. __________________ U.S on FZ6 Wayanad- LEH 09 - Coorg - Muthathi - Bye Bye 2008 - First G2G - 07 Photography Last edited by Rockkyyy; 09-17-2009 at 01:07 PM.

09-16-2009, 10:36 PM	#2 (permalink)
Aryan Senior Member Join Date: Jan 2006 Location: New Delhi/ Shillong Posts: 18,275	Topic Approved. Good work Rockyyy. Thanks for sharing. __________________ ...in search of that perfect world - My Travel Blog :)

09-17-2009, 10:05 AM	#5 (permalink)
Technician Senior Member Join Date: Jun 2009 Posts: 240	The above method of putting a copper wire is also a jugaad to make a smaller main jet out of a bigger jet. If you insert the wire while calculating the size of the wire precisely, you end up making a smaller jet and can use it anywhere. I have been using one of this jugaad in my CBZ in plains for many months. No problem, no extra heating, safety for valves, etc. I tried to make a jet No. 109 out of ZMA main jet No. 125 in this way. I am satisfied with the results. __________________ The Original CBZ

09-17-2009, 10:19 AM	#6 (permalink)
rachitkohli HardRider Join Date: Dec 2008 Location: New Mumbai Posts: 1,930	Hey thnkx Rockky.. that was the exact info everybody around must be looking for who have been or are going to head mountains..! Even I faced this problem, the bike use to give jerks as if no petrol while climbing. I kept the RPM within 3-4k so I didnt faced much problem due to it, yes its true, you wont get that much torque as required. But fixing up the throttle within range of 3-4k while climbing up should not be an issue. Due to getting freezed it was damn difficult to hold on. This solution seems to be really wonderful & next time will certainly give a try when my luck takes me to LEH __________________ ..»».. I will rather ride my Bike thinking about God, then sitting in a Temple thinking about my Bike.. »».. Mumbai - Leh - Mumbai June '09 :On xBHP: Ride With me to Leh Blog : Mumbai - Leh - Mumbai : 21 Days, 6500kms. Journey to Heaven..June'09 GreatIndianRide - West India on a 110cc for over a month 2nd, Mumbai-Leh-Mumbai : July'11 (blog coming soon)

09-17-2009, 10:41 AM	#7 (permalink)
jd666 Senior Member Join Date: Sep 2009 Location: Gurgaon/Faridabad Posts: 3,320	interesting indian ingenuity !!! good share!! __________________ The latest RXZ rebuild pics, updated July 2011 - http://www.xbhp.com/talkies/thumpers...tml#post669927 My offerings to the gods of speed - - Yamaha R15 - Yamaha RXZ 5 speed

09-16-2009, 10:59 PM	#3 (permalink)
Akshay Jain Tourer Join Date: Feb 2007 Location: Delhi Posts: 78	yeah .....thats a very good sharing from you ....thanks and yeah on leh airport road there are lots of mechanic and spare parts shop

09-17-2009, 04:54 AM	#4 (permalink)
Akshay. Akshay4384 Join Date: Oct 2008 Location: Ambala/Chandigarh Posts: 270	A simpler solution is to remove the snorkel or get a K&N,that makes up for the lack of air. I have never ever faced powerloss on my Zma at 12000Ft+ altitudes. mine runs on a K&N RC-1060 with 140 main jet.

09-20-2009, 04:58 AM	#8 (permalink)
aarunn Senior Member Join Date: Sep 2008 Location: TRIVANDRUM KERALA Posts: 817	A great Piece of info..... Hats off da

09-20-2009, 02:08 PM	#9 (permalink)
moeed The Addict! Join Date: Oct 2008 Location: Hyderabad/On the highways Posts: 2,396	Nice info there! Thanks for sharing!

09-26-2009, 10:41 PM	#10 (permalink)
karthik_k Member Join Date: Nov 2008 Location: CHENNAI Posts: 31	thanks for the share mate...great info

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