Topic Approved. 52 to 48 kmpl is not a big deal. Smoothness surely is.

But still the info is confusing. Is Engine reboring actually needed?

From the things you posted, it appears that oil is leaking into the combustion chamber. This might be solved using new piston rings too, if the piston and block are not damaged at all.

I suggest that you first try to find out where the damage is... And how do you feel when you kickstart it? Any difference in feel or sound?

Sounds like classic problem of the piston rings gone busted, if the piston rings are busted the oil enters into the combustion chamber and burns oil , thus the smoke and reduction in amount of oil.
To conform it apart from smoke and reduced oil level, just remove the primary and secondary spark plugs , if there is oil deposit on the spark plug electrode , then you can conform that its the problem of piston rings.

Cheers
Ride Safe
Krishna

@karthickj- buddy get compression check (dry as well as wet)...this can help you pinpoint whether the valves or rings are leaking....if the culprit is the ring and bore then its better to change piston-bore kit rather than boring....new piston-bore kit will cost around INR 1700 + labor cost. If the bore is ok then you can settle just by changing the rings as suggested by Samarth

basic info is missing-

• how many kms old?
• year of purchase?
• any other service history?
• any modifications done?
• any other symptoms like loss in power/acceleration/top speed?

if it is a problem with bore, changing only the piston rings is just a quick fix and wont last long.

what is the meaning of "shud cost 3K and 2 years warranty"...? i can understand the price part but not the warranty one?

Guys Sorry missed out some important notes-

My bike purchased year is 2008, now the usage is 33,000 km,

two year back i had issue with scissoring gear in clutch box. some noise coming so I replaced that scissoring gear. But there was not smoke after that.

Tills three months back I did not had any issues. Just after using that engine oil flush this problem started.

Some changes now I can see -

Morning the bike is not starting that easy. I use to start by kicker only. At least 20 kicks required to start. Once started white smoke coming out but during the ride there is no smoke. If I increase the throttle and raise the engine RPM above 7000k smoke is coming.

I dont see any change in the bike sound. But when I keep my finger into the silencer hole I can see my finger is dark black.

Some oil leak out of the engine case , near the gear shifting rod, engine oil level indicator.

About the 3k cost is engine reboring. My area mechanic (local mechanic shop guy) told to do engine re boring. and they charge 2k with some spares need to be replaced so the total cost wud come around 3 k and they give warranty for 2k

+1 on that, a new barrel & piston kit will outlast any re-boring you do. Also check for valve guide wear.

first rectify the oil leaks from 3 locations you mentioned.

Thanks guys for your support. This weekend Im planning to give my bike for complete inspection. The following are my doubts.

1) I wish to open up the engine case and check for damages and cause for oil leak and smoke.
2) what would be the approximate cost for dismantling the engine case and replacing the rings or the piston if damaged?
3) Is there any chance of other related parts which might have got damaged.
4) I just want to know what will be approximate cost.
5) What shud I ask the service mechanic to inspect for. Just need the technical terms. pls guide me.

And finally one more doubt. In the past one year I lost my bikes original power,pickup and smooth gear shifting. I just want resolve these issues also.pls guide me what to ask for the mechanic to do. Pls help me ASAP

Thanks

Replacing piston/rings and reboring the cylinder will cost around 2500-3000.
Check/replace engine case packings and oil seal of gear lever hole for resolving oil leackage. Check for shake in gear lever which could be a reason for oil seal going bad.
Check for condition of piston/rings when opening the engine, check for scratches in cylinder(bore).

As your bike is burning oil and producing smoke, mostly your engine would've lost compression due to worn rings/bore which is the reason for poor performance.

Hi all ,

I finally gave my bike to one of my trusted mechanic in Vadapalani , chennai. He opened my bike and inspected.

The rings are worn out, scratches in the piston and there is shake in the lever inside the engine. The inner side of the spark plug looks completely burned out, Timing chain is also worn, Gear spring and lever was damaged, Crank shaft to be replaced

Almost 10.5 k is estimated cost for my bike including labour charges 1.5k.

And also he recommended not to do re boring for 4 stroke engines. It can be done if you are going to sell the bike. And he says 95% of the performance will be like a new bike. And he told he will wash out the silencer since it is fully occupied by carbon.

Please pass your suggestions to check for any other stuffs

My personal opinion - 10.5k for engine overhaul and gear repair seems to be too higher, that too at local garage.
Please check with a BAJAJ ASC for the same repair. They might be ready to give you warranty too for engine overhaul service.

@ the thread Starter, going by your post, pls. find the below prices of spares in Coimbatore. More or less the total work should cost you Rs.7900/-. If the Mech you told is carrying out all the below work at the prices listed, you can very well give it to him negotiating a bit on the labour part.

Cylinder kit New - 1700/-
Crank shaft Setting - 1300/-
Head lathe work for Valve Seating - 300/-
Clutch Assy New - 1500/-
Cam Shaft - 700/-
Rocker Arm - 300+300/-
Timing Chain - 200/-
Valves - 300/-
Scissor Gear - 500/-
Packing Kit - 500/-
Engine Oil - 300/-

Cheers
Ram

1 Fork oilseals / fork oil/fork boot clamp 221.00 2 Front disc.pad ,cyl.washer kit & lathe work 592.00 3 Front & rear wheel bearings 355.00 4 Rear stay bush kit complete 228.00 5 Wheel cush rubber / sprocket bearing 230.00 6 Water washing 80.00 Labour charges 475.00
jobs carried out

Fork complete overhauling 2181.00
Self motor overhauling

Front wheel cylinder overhauling

rear stay removal & bush kit replacement



Engine job



1 Engine bearing (4nos) 638.00 2 Packing kit complete 192.00 3 oilseals kit complete 106.00 4 o'ring kit complete 98.00 5 Engine paste 40.00 6 Connecting rod,pin,bearing & lathe charges 1200.00 7 Gear shifter spring kit 42.00 8 Gear stopper 30.00 9 Gear selector arm 192.00 10 Cyl.block assembly/chain tensioner 2268.00 11 clutch assembly complete/cl.bearing 1412.00 12 Engine valves kit/valve guide & lathe charges 600.00 13 Engine head cam shaft assembly 634.00 14 Rocker arm 388.00 15 Magneto balls kit & bush 141.00 16 Head dummy 30.00 17 Timing chain /chain pad kit 344.00 18 C/shaft keys & nuts 66.00 19 Clutch nuts 42.00 20 Clutch bell re-conditioning lathe charges 350.00 21 Engine oil (1.2l) 300.00 22 Thinner & kerosene for cleaning purpose 120.00 23 Engine complete overhauling charges 1500.00




10733.00

here is the attachment of my bike charges.