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**dhaya** · 12-13-2011, 08:42 PM

solution

hi,

U told have change back of tci unit k. whether u check magneto weight depend of compresion and valve spring.suppose its more stiff it make problem while giving throtle..

**lijok** · 12-13-2011, 08:56 PM

Originally posted by dhaya View Post

hi,

U told have change back of tci unit k. whether u check magneto weight depend of compresion and valve spring.suppose its more stiff it make problem while giving throtle..

I,m not sure I got you. Can you please elaborate in simpler terms please...

**kb100** · 12-13-2011, 09:53 PM

Originally posted by dhaya View Post

hi,

U told have change back of tci unit k. whether u check magneto weight depend of compresion and valve spring.suppose its more stiff it make problem while giving throtle..

what has magneto weight got to do with this ,his bike running on stock ignition system, also please loose the sms lingo and use understandable english , cant figure out what you are posting

**Joel** · 12-14-2011, 01:24 AM

^Well thats another story for another day..lol

**lijok** · 12-14-2011, 02:14 AM

Originally posted by Joel View Post

^Well thats another story for another day..lol

So there is a story... mmmm interesting...

Ok, todays update:

Since yesterdays incident of power returning, till today evening there were no issues. Now, today when coming back, I was ripping away in joy, when I see police patrol ahead, close throttle and slow down. After passing them, I slowly open throttle, so as not to make much sound... and once clear, wring it to full.. nothing.... speed just climbs steadily. So I close throttle, open it.. repeat... nothing happens for some 4-5 kms. Then yesterdays same thing recurred, with throttle twisted open to max, suddenly the bike starts pulling away... Since then, no issues till reaching home, which I took a longer route...

One thing is for sure.. when the bike comes back to "life", it occurs when the throttle is completely open.

**kb100** · 12-14-2011, 06:03 PM

Originally posted by lijok View Post

So there is a story... mmmm interesting...

Ok, todays update:

Since yesterdays incident of power returning, till today evening there were no issues. Now, today when coming back, I was ripping away in joy, when I see police patrol ahead, close throttle and slow down. After passing them, I slowly open throttle, so as not to make much sound... and once clear, wring it to full.. nothing.... speed just climbs steadily. So I close throttle, open it.. repeat... nothing happens for some 4-5 kms. Then yesterdays same thing recurred, with throttle twisted open to max, suddenly the bike starts pulling away... Since then, no issues till reaching home, which I took a longer route...

One thing is for sure.. when the bike comes back to "life", it occurs when the throttle is completely open.

psr sirs post comes to mind.....

Originally posted by psr View Post

Throttle slide not moving freely with Vacuum.

**Revverend** · 12-14-2011, 08:09 PM

@lijok Well exactly the same thing happened to me on my last ride. 4k to 7k was so bloody sluggish i had to pin the throttle and the bike was worse than a moped.no amount of afr settings worked.rode like that for a 100 kms to belgaum.took it to an asc and the problem was a busted carb diaphgram .change that and revert back.costs 550 bucks and it solved the problem.

**lijok** · 12-14-2011, 08:38 PM

Originally posted by kb100 View Post

psr sirs post comes to mind.....

Originally posted by Revverend View Post

@lijok Well exactly the same thing happened to me on my last ride. 4k to 7k was so bloody sluggish i had to pin the throttle and the bike was worse than a moped.no amount of afr settings worked.rode like that for a 100 kms to belgaum.took it to an asc and the problem was a busted carb diaphgram .change that and revert back.costs 550 bucks and it solved the problem.

Ok so the throttle slide and diaphragm are the prime suspects now. Will have these checked and update here...

**ashu_nik** · 12-14-2011, 10:52 PM

^ I am also facing the similar issue with my 220 FI. And also running on Joel's piston and 230 cc setup (looks like we are sailing in same boat)

In my bike I am also suspecting dirty throttle body. Will be getting it cleaned this weekend and get the CO reset to a little rich AFR. Keeping my fingers crossed.

Unfortunately, The problem amplifies when big bore is bolted on.
Joel Please share your wisdom on this ...

Are we heading in right direction ??

**Joel** · 12-17-2011, 03:02 AM

@Lijo - Please check on ur carb diaphram. Since its vacuum type, a stiffer rubber diaphram will foul your slide movement and hence reduce the overall performance. You still have your old carb and I just remembered that I had a similar issue with my fiero a few years ago. The BS29 diaphram normally packs up after 1-2yrs of use.

**nox2505** · 12-17-2011, 09:21 AM

Originally posted by lijok View Post

All expert troubleshooters out there - I desperately need your help to solve a mysterious issue with my Apache RTR180.

Short history:
1. Bike is 2.5 years old, currently 45k on Odo
2. Installed a K&N R1060 filter just after second free service, converted to full DC with coil rewinding etc, swithched to bixenon HID 35W, later upgraded to 55W
3. Early in Jan 2011, ran into engine trouble due to low oil (still a mystery how it happened). Changed cylinder kit, crank under warranty after a bit of struggle with SVC.
4. After running the above bore for 3k kms, got a 190cc big bore from Joel.
5. Hardly 2k kms into the big bore, found out that the piston got damaged due to faulty installation.
6. Reverted back to stock bore (from pt 3)
7. Decided to do Leh in Aug, 2011 by around June. Hiccupps started - at low rpms, b/n 2-4k rpm. Showed to SVC at Cochin, they said RTR is like this only!
8. Taking the risk, went off to Leh. Did Delhi - Amritsar - Srinagar - Rangdum - Kargil - Leh - Manali - Delhi in Aug 2011, with absolutely no issues
9. Reached back home from Leh, the next day hiccups resumed. The new issue of power loss also started - bike would not climb above 6k, sometime 7k rpm in any gear
10. Changed the TCI unit, TPS unit, throttle cable etc - no use
11. Opened the carb, found the main jet was 105 instead of 125, thanks to the mech who installed the big bore (from pt 4,5). Replaced with stock main jet - hiccups vanished, power loss continued.
12. Removed the DC conversion changes hoping its electrical issue - no use. Reverted to DC for next point.
13. Nov end - went to Banglore, visited Joel, reinstalled the big bore with new semi-forged piston, got FFE with db killer, Simota conical air filter. During test ride after installation, found no issue what so ever, but being run-in period did not test completely.
14. Rode back from Bangalore to TVM via Cochin, upping the top rpm every 100kms. At Cochin, the run-in distance of 500kms +100km was done. Rode to TVM at full throttle. Felt like I was riding a mini rocket. I was so so so so happy.
15. After reaching home and sleeping for 2 hrs, went to offie, came back. No issue.
16. Next day, going to office - started the bike, climbed the uphill from home to main road, hit the throttle leaning forward, not getting thrown back, bike gains speed in a very sedate manner, just like before installing the upgrades (pt13)... I'm heart broken.

Current situation: no hiccups, sure its not engine issue as bike gains good speed in excess of 100kmph - given the space. AFR is proper, spark plug is brownish black in color. Not due to DC conversion as removing and testing for 2 weeks did not yield any results.

Things replaced as part of troubleshooting: TCI (ignition controller in RTRS), TPS, Throttle cable, spark plug etc
Things not changed: Only carb and ignition coil.

Currently the bike is not performing like an RTR (Race Throttle Response). It gains speed in a very very sedate manner - just like a underpowered 100cc bike. The throttle response is very very slow/sluggish.

What could be the cause? Please help me with your thoughts and inputs.

Thanks,
Lijo

Check the following:
1. Valve timing- fairly less chances of it being issue.
2. Compression pressure.
3. Exchange carb for a day with some fellow. It will help finding out if carb is culprit.
If its the issue, check slide spring, diaphram and jets (most probably the air jet will be culprit)

**UTKARSH STUNTY SHARMA** · 12-18-2011, 11:59 PM

very serious problem with my rtr

hi guys, i own a rtr 180, and my bike history goes as follows
1.bought in april 2011 did 500 kms gave for first service.
2.1200 kms on odo, Got some serious heat issue so shifted to castrol power 1 no good
3. At 2500 kmsDue to a hell lot of stunting (in short fuc*ing up the bike) had to replace tyres to 120 zap-cc rear and 90-90- zap fs front.
4. Had some power loss issues which actuall was worn out clutch plates but i was a fool and got k&n , bosch iridium, splitfire, installed on my bike,no upjetting though.
5. The bike used to jerk near 9k prm and never crossed 10 k after install
6. Used all that without issues till 6 k kms, then though to upjet, tried many jet sizes, drill etc, but all restricted my bike's rev to 8k only, i was told by many mech's that opening the carb many times will kill it.is it so
7. Had to finally set in with stock jets and removed k&n at near 7k kms, believe me the bike ran supe smooth.
8. I got the clutch plates replaced at 7k, the bike regained its lost power and yamahalube 20w40 did total justice.
9: soon after that i started facing issues with lags, jerks etc, showed it to the asc and they diagnosed, valve leak, worn out cylinder kit, the sole reason being runing too lean with k&n.i started cursing myself
10. I got joel's big bore and installed along with new valves, seal and timing chain.
11.completed runing in and took it for a blast, the bike performed superb and touched nice speeds of 130-135 which it newer saw earlier as me being a owerweight rider.
11. Being impressed with the bbk, i sent my bike's head to joel for porting and got a ffe too. Installed the whole setup and i just couldnt believe my eyes, i didnt sleep the whole night,as the bike was touching the 100 mark so damn easily, but......my happiness was short lived as next morning started a problem.
12. When i started with the bike as soom it touched 6k rpm in first gear, the bike started doing phat phat phat from the head area and a visible compression leak was identified. Got the head opened got a new gasket installed it and started revving. The bike went fine for 20 kms or so and again the same leak.
13. Talked to joel and he said to get the engine head and bore re-machined or re surfaced by scrapping some metal and getting new engine packing along with it. Did so , revved the bike all the way . No issues till the night.

Current problem

started revving this morning again bike started doing phat phat phat from the head and and that moment i was pissed off. The bike does phat phat and leaks compression in all gear after 6k rpm's. But the same cant be noticed if we rev the bike on stand still, plzz plzz plzzz , some senior experienced members get into this.

Thnxx in advance
regards
utkarsh

**Vignesh vnktrmn** · 12-21-2011, 04:20 PM

@ lijok did you check the integrity of the throttle cable?
I had the same issues on my stock a180. Realised that the throttle cable splits into two, one endgoes to the carb, the other to a sliding switch connected to the Control unit(TCI). The cable going to the switch had snapped and the bike was giving me the same problems. Now I am not aware if that same switch is called the throttle slide which Joel has asked you to check. Maybe that the sliding switch is damaged . Mine had once got moisture in it after the servicing wash it caused the bike to splutter upto about 4K rpm then cough all the way upto 6K rpm but behave normally after this rpm range is crossed.

**Karthik Mathur (Orange)** · 12-21-2011, 05:16 PM

Hi, i am a total novice when it comes to extreme technical matters in bikes.
But i have heard that in carburetors, at lower and mid RPMs fuel is supplied through a particular thing and at higher revs through jets.
Could the former thing be the problem? and as at higher revs it behaves properly, the jets would be okay
(i dont know whether the former are also called jets)

**Drifty** · 12-21-2011, 06:45 PM

Originally posted by Vignesh vnktrmn View Post

@ lijok did you check the integrity of the throttle cable?
I had the same issues on my stock a180. Realised that the throttle cable splits into two, one endgoes to the carb, the other to a sliding switch connected to the Control unit(TCI). The cable going to the switch had snapped and the bike was giving me the same problems. Now I am not aware if that same switch is called the throttle slide which Joel has asked you to check. Maybe that the sliding switch is damaged . Mine had once got moisture in it after the servicing wash it caused the bike to splutter upto about 4K rpm then cough all the way upto 6K rpm but behave normally after this rpm range is crossed.

What you are referring to is the Throttle positioning sensor(TPS),he had replaced that too!

@Lijo- Did you find what's the culprit?Please do update us.

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Mysterious power issues with my RTR180

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