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Rust and Other Issues - Bajaj XCD135

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  • #1

    Rust and Other Issues - Bajaj XCD135

    Today being the end of the first week of July marks almost 3 years of owning my beloved XCD135, I thought I'll fully fix her up for our 3rd year anniversary :lol:.. I even have plans for upgrading her a bit but only after fixing her up and if I have monies.


    1) There are major issues of rusting. I wish I stayed in an apartment complex with underground or covered parking but unfortunately my 20 year old society wasn't built like that and so my bike has been exposed to the elements for the past 3 years. Add that to Bajajs shit quality and you get this. Anyways while the rusting seems to be affecting multiple regions, it seems to be really bad around the chain cover and the engine exhaust line (sorry if I'm getting these parts names wrong).


    1) (a) For the chain cover, I was wondering whether I could get rid of it entirely i.e go open-chain. But that would require changing to a special chain I suppose? I don't mind the extra spray maintainance but what are my odds of me finding a compatible chain to complete this mod. I don't suppose the P135 or Discover 125ST chains would fit...? If not this then, do you recommend removing the rust of the chain cover (if possible) or just buying a new chain cover altogether?









    1) (b) For the engine exhaust pipe, is that pipe too far gone or can that pipe be de-rusted (lol?) and used again? (Cause the ends look pretty bad - check pic 2 and 3).








    Also near the point where the pipe connects to the engine (pic 3), there seems to be some odd problem which is causing the bike to make weird noises at exactly 5k and 7k rpm. Its like a loud 'trilling' noise (which you'd expect from a broken silencer) only that its coming from that area and only at that rpm.

    Its been happening for some months now and even the Bajaj service centre chaps have no idea whats causing it and why. They told me to take it to a local repair shop as those people were more likely to find and repair the problem rather than outright start replacing parts in an attempt to fix it .

    Hope you'll guys can help me with this for now. Thanks in advance
    Tags: None
  • #2
    Query Approved

    Do you stay near a coastal region? Because thats an insane amount of rust.

    For the chain, I would say, lose the chain cover and lube regularly till the chain + sprocket kit eventually goes bad. After that you can pick and choose according to your budget. O-Ring chains are more expensive than regular chains, and even on a bike like the CBR150R, Honda uses a regular chain with only half chain cover. So it definitely can't be that bad.

    As for the exhaust pipe, I would request the other members to help out.
    Advice is a form of nostalgia.
    Dispensing it is a way of fishing the past from the disposal, wiping it off, painting over the ugly parts and recycling it for more than it's worth.

    Antz Travelz!! | South India Exploration Ride | Leh Triplog (Work in progress)

    Comment

    • #3
      Originally posted by antz.bin View Post
      Query Approved

      Do you stay near a coastal region? Because thats an insane amount of rust.

      For the chain, I would say, lose the chain cover and lube regularly till the chain + sprocket kit eventually goes bad. After that you can pick and choose according to your budget. O-Ring chains are more expensive than regular chains, and even on a bike like the CBR150R, Honda uses a regular chain with only half chain cover. So it definitely can't be that bad.

      As for the exhaust pipe, I would request the other members to help out.
      Thanks . Well thats the irony of it (pardon the pun) - I stay in Ahmedabad, Gujrat. But then again the bike hasn't been covered or given any form of protection against mother nature for almost 3 years now.

      I'd rather keep the existing chain + sprocket kit as I believe this gave way 3 months back so I assume the parts are pretty new. Anyways, so to go open chain its as simple as getting a new O-Ring chain with a compatible sproket right? Would the engine/transmission (where ever the other end of the chain connects to :lol be compatible with the chain? Also would it be advisable to wait untill the end of monsoon for this mod or would it not make much of a difference if I do it now instead of later?

      Alright. Let me know if you'll guys need macros or more pics of the exhaust line.

      Comment

      • #4
        Any advice on the exhaust line and the chains guys?

        Comment

        • #5
          Just get the chain cover and the silencer powder coated and the entire bike polished with Formula one polish. Get the chain cleaned with a chain spray and then a thick coat of grease, Do all this and ur good to go!

          Comment

          • #6
            Thats my last resort, any further help on going open-chain? Cause I would prefer that as I don't really like the look of the chain cover and anti-rust coating is the last idea on my mind :lol:

            But about the exhaust line? Is that part too far gone or can I do what Ripper said for that part too?

            Let me know if you anyone wants more pics of that exhaust line....

            Comment

            • #7
              Rust is an old enemy of automobiles. You can ignore it, but cannot forget .

              Open chain, the best option is to go O-ring. Else, if you are city dweller normal cross-link chain doused with thick grease is more than enough, though regular cleaning will be a task every month.

              Silencer, either get it painted with heat resistant paint or douse the whole length with anti-corrosion spray (OKS has this). My experience with old engine oil on exhaust pipes has been positive. I used to do it on my dad's TVS moped. It worked brilliantly during Chennai monsoon's. If bike's paint is affected, then go for Hard Wax polish such as Waxpol/3M. They are effective for longer duration than liquid types.Waxpol Silicone polish is very good one, but very very hard to find in market.
              Safe riding prolongs life (bike & rider & public)

              Comment

              • #8
                Originally posted by Prith View Post
                Open chain, the best option is to go O-ring. Else, if you are city dweller normal cross-link chain doused with thick grease is more than enough, though regular cleaning will be a task every month.

                Silencer, either get it painted with heat resistant paint or douse the whole length with anti-corrosion spray (OKS has this). My experience with old engine oil on exhaust pipes has been positive. I used to do it on my dad's TVS moped. It worked brilliantly during Chennai monsoon's. If bike's paint is affected, then go for Hard Wax polish such as Waxpol/3M. They are effective for longer duration than liquid types.Waxpol Silicone polish is very good one, but very very hard to find in market.
                O-ring sounds like the best option as regular cleaning for the normal chain would be a PITA for me. So finally how do I go about buying this chain? I suppose I would need a sproket kit too? How much would all this cost?

                Okay I will get the silencer rust coated but only after I can get that trilling noise at 5k rpm fixed. I'll be taking the bike to a repair shop tomorrow so he'll have a look at that pipe too. I wish I could do what you suggested Prith but I'm pretty much useless at these things, so basically how much should I pay the repair chap to have the anti-rust coating done?

                Comment

                • #9
                  Originally posted by Prith View Post
                  Silencer, either get it painted with heat resistant paint or douse the whole length with anti-corrosion spray (OKS has this).
                  Hi Prith,
                  Regarding the heat resistant paint, will this withstand high temperatures? Won't it effect the heat transfer, like lets suppose i paint the cylinder block of the engine with this paint, will the engine get hotter while running?

                  Thanks.

                  Comment

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