rahuldevnath

Guys, this is the first time i'm posting a query in Help section, but I'm quiet frustrated. The bike in question is my less than 2 months, and 3500Km Old Pulsar 220 Dtsi.

The problem is that my bike doesn't crosses 8K RPM (in any gear). I have touches 140 on speedo, and done several high speed runs. But it takes ages to reach to 8K RPM from 7.5K, and after that it doesn't bulge.(The Bike redlines at 10K!)

On My P180 I could frequently red line my bike, and could even go till rev limiter would kick in.

I have tried all the variable, cross winds, pillion, distance, gear shifting pattern, Carburetor Tuning etc. My bike is well serviced with Motul 5100T.

I believe the Tappets are too tight, that's from my understanding that tight tappets causes this and vice versa, but sound from the engine tells me that tappets is set on the looser side.

(1) What could be the cause.
(2) If the culprits are tappets, how can adjust them myself, a little understanding of no. of torques required would be appreciated.

Mech Gurus kindly help.

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abhijeet080808

Well, to adjust tappets, you will need a feeler gauge. First set the bike at TDC. Firstly remove the spark plug, to make the engine easier to rotate. Now, open the flywheel cover located on the left side of the engine. Rotate the engine till you see the TDC mark through that cover. Now, you need to open the tappet cover and loosen the tappet nut. There is a small screw type thing above this nut, which can now be turned either way to adjust the clearance. Now, use the feeler gauge to set the gap between the cam and the rocker arm as per specs. Now holding the screw type thing is the same position, tighten the tappet nut. Screw back the tappet cover. Use some rubber sealant here. That's it.

And, I don't have any pics with me!

EDIT - But a 3000kms old bike usually does not have tight tappets! Are you sure it is not some other issues?

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honda_vings

even my uni takes longer time to rev up 7.5 k onwards but only on fifth gear
first 4 gears revs up normally quickly till 9k rpm
i think 5th gear is d culprit
shall i giv d gearbox for by-pass surgery to the mechanic ?

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prakash_mvpa

I think tappets are set when Engine is Hot?Some says to be done when cold.

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honda_vings

the honda manual says to set when cold
the rpm tends to be heavy in 5th gear in7.5k+ rpm range only
my expert mechanic adviced me not to touch the tappet settings for such small issues.
can oil filter be the culprit here ?
manual recommends to replace the oil fiter after 20,000 km or 12 months whichever is earlier.
i have not changed the oil filter since 4.5 years and has done only 17000 kms

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abhijeet080808

Set it either hot or cold. But clearances are more for a hot engine. Also, manual specifies cold clearance specifications only.

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insane_x97

tappets could be,
bajaj uses multi cdi mappings operated with a switch at carb side.check it also.
check for both the plugs working.
you said carb tuning!! any performance mods done??, revert back to stock and check again.

abhijeet080808

Yeah, the TPS switch is important!

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abhichotu.abhi

the problem is with your rear disc brakes, they are running tught.. check them..
my friend faced same problem probably a year ago, whenever his bike reaches 7K rpm in 5th gear, there is almost 1inch of throttle but when he pulls the left throttle then too the engine responds to throttle change but the bike refused to go above 7K, finally the problem was sorted out that the rear disc brakes were faulty, they were replaced...