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Immediate help required to bring my XCD 135 to its early glory

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  • Great news........Now people here dont start bashing me for being extravagant....I love my bike( and I guess all of us here do) to such an extent that I dont mind spending a huge fortune,if it is for the well being of my bike.Now what I did today.
    1.I noticed that spark from one of the plug cover was not normal at all....It used to produce spark once a while in 5 sec or so...which I thought was the cause of missing.I decided to replace both ignition coils,and decided to play around with the electricals this time.Since charging current was Ok,I decided to skip replacing the armature coil(which the SVC guys were pushing for)...I bought 2 ignition coils(total damage Rs 300[mrp Rs 370]),and came home,had decided to do a DIY job,along with my friend,who proves as a great aid for such jobs.i also replaced the spark plugs with NGK Iridium ones,and when I started the bike,no fuss,no miss whatsoever!!!Mission 1 accomplished!!
    2.I was also unable to raise the idle rpm,which some of you may remember.I also had a very non linear acceleration issue,which thanks to dear xbhpian Ateesh aka Honda_CBF,got sorted out by almost 80%,but still,it had scope for 20% improvement.Now my friend has good contacts in Bajaj Auto and thus every body at service seems to respect him,He got a new Carb for me,at the condition that we'll return it if it doesn't show any improvement.When we installed the carb,tuned it and took it out for a ride,oh man....the bike had completely transformed!!!Throttle response was superb,coupled with flawlessly linear acceleration...The bike now grunts,grunts with anger and pickup was such that for the first time,I felt like I was going to fall...I just cant explain the feeling!!No startup issues,nothing+added to great accn and drive.I was immediately sold on the new carb...but where was the money...I immediately cancelled a COD order of Galaxy S3 from flipkart....and voila...cash was arranged....!!Now the interesting part,MRP printed on Carb's box was Rs 1557...but my friend got it for Rs 1200 Rupees,as that was the price the dealerships get the carb from the manufacturer..So total damages at the end of the day-Rs 1500...But hey,I'm not complaining...All I wish to see is that how the bike starts from cold tomorrow morning...If Its Ok,then I'll be the happiest person on earth,with a Galaxy S2,of course!!!

    Honda_CBF---You are most welcome to Ranchi to have a ride on my bike!!!

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    • Great news indeed. Really happy that you sorted out everything that too like a pro.. Start with minor doubts, sort things, move ahead to next doubt. Well done man don't have any plan for ranchi now, but we'll meet soon, as a proper g2g!
      http://www.facebook.com/ateesh.kumar

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      • ^^ Sure!!!

        Yesterday,for the first time in the last 4 years,I left my bike outside the garage(but within the secure campus)just to make it as cold as possible.Had to wake up at 4:30AM just to check whether the cold start issue is there or not...Book says that 1st start should be by kick,but I decided to skip.Remembering the Almighty,pressed the starter,and with one touch,the bike came to life,Infact,the autochoke raised the rpm to about 2500,and it went on till about half a minute,and then the idle rpm dropped to about 1200.I guess for the first time since I bought my bike,I saw Autochoke in action...So with replaced Carb and Ignition coil,thermAL sensor also starts to work..Strange!!!
        However,since the major issue seems to be wiped away now,a small glitch caught my attention.My bike was in 2nd gear,and stalled at an intersection..WHen I pressed clutch and pressed self,nothing happened,despite all honking behind,I was adamant that the bike should start in second gear.It did,but after a delay of about 5-6 sec..Is that normal??While pressing self in gear with clutch engaged,I felt that bike tends to move forward a bit...I should better say that clutch was not controlling the bike completely(about 5% power was still transmitted to wheels)...Does it indicate a clutch adjustment goof-up,or a gone clutch altogether??I may also add that my bike does 52kmph @ 5th Gear @ 4000rpm(a healthy XCD 135 does the same),is in stock condition(no sprocketing)...But sometimes I notice a bit of slip when I kick.But only once or twice in hundred...What do you guys think??What kind of adjustments do I need to do??

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        • Regarding your clutch try increasing its free play by 1mm. What you are experiencing is called clutch drag (opposite of clutch slip) i.e. Clutch plates doesn't disengage completely. Also, it is also possible that everything with clutch is ok, but even so power transfer from engine to gearbox happens it is because of oil, yes engine oil can also do that. For full check up do this: > start engine with bike on main stand. > press (disengage) clutch, shift to 1st gear. > you'll notice rear wheel spinning, now try to stop the wheel with your foot, it must stop without stalling the engine (drag your footwear on tire wall, do it like you are applying brakes on some four wheeler, this way you can monitor how much pressure is needed to stop it spinning).. > keep the pressure constant to stop the wheel spinning > now start leaving the clutch, slowly. > at ''half clutch position'', wheel should start spinning with lower idle RPM (keep the pressure constant on tyre wall) > increase the pressure on tyre wall to stop it spinning, RPM should come down further, but engine should not stall. One can also hear the sound of slipping clutch plates from crankcase (with little throttle, wheel should start spinning & as soon as throttle is closed wheel should stop) > engine should only stall when you leave your clutch to full or near full, but without throttle it should keep spinning the wheel. . With 'half clutch position' I don't mean that clutch lever should stay exactly at 50% of travel. It can be anywhere. But not too close to the full pressed position or full let out position. What I mean, is that you should get the feeling of clutch bite/friction. Btw, when was the last time you changed the clutch plates and how old are they, in terms of kilometers?P.S. Do this test on warm engine, not hot, not cold. And don't do it for long, as you can guess, it causes clutch slippage.
          http://www.facebook.com/ateesh.kumar

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          • I tried doing what you have mentioned,with clutch engaged(presses) and in 1st gear,the rotation is very very minimal....I mean I can stop it even with my fingers,its that low.I tried adjusting the free play...will report tonight about the condition.
            BTW,Age of Clutch Plates-Around 3000kms....Had Changed it last March.....Engine oil is Castrol Power 1 Racing 10W50 Fully Synth.
            Last edited by SWIFTSHASHI; 02-01-2013, 02:21 PM.

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            • Originally posted by SWIFTSHASHI View Post
              I tried doing what you have mentioned,with clutch engaged(presses) and in 1st gear,the rotation is very very minimal....I mean I can stop it even with my fingers,its that low.
              then there should be no problem in first place.. And when you press the clutch lever, its called dis-engaged. (because clutch plates are not in contact with flywheel) and vice versa.
              http://www.facebook.com/ateesh.kumar

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