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**Sunny** · 10-12-2009, 06:17 AM

Query Approved

**abhijeet080808** · 10-12-2009, 11:57 AM

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?

**honda_vings** · 10-12-2009, 12:18 PM

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 ?

**prakash_mvpa** · 10-12-2009, 12:21 PM

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

**honda_vings** · 10-12-2009, 02:29 PM

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

**abhijeet080808** · 10-12-2009, 02:50 PM

Originally posted by prakash_mvpa View Post

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

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

**insane_x97** · 10-12-2009, 04:06 PM

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** · 10-12-2009, 04:08 PM

Originally posted by insane_x97 View Post

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.

Yeah, the TPS switch is important!

**abhichotu.abhi** · 10-13-2009, 12:58 PM

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...

**rahuldevnath** · 10-13-2009, 02:25 PM

Originally posted by abhijeet080808 View Post

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?

Thanks Abhi for the detailed procedure. I Tried, it seems at least with a spanner, the nut does not rotate at all. I didn't try extreme force either. Does the nut being absolute tight means, the tappets are tight?

I think I will take to AutoService one of theses days.

Originally posted by insane_x97 View Post

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.

Originally posted by abhijeet080808 View Post

Yeah, the TPS switch is important!

The Bike is absolutely stock. I just tried tuning the ASR for rich as well lean mixtures. The TPS seems to be perfectly moving.

Originally posted by abhichotu.abhi View Post

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...

Disc Brakes aren't the culprit here (wish it would have been), both the wheels are quiet free, in fact my rear disc is not effective these days, and the wheels are free, there's no heating of the disc either.

Overall it seems my engine is not revving freely, and after 8K in any gear it does not go beyond it.

Point to be noted that I have started ripping my bike recently, and I could never cross 8K ever on this bike! Though it has touched 140Kmph on Speedo.

**manohar_manu** · 10-13-2009, 02:45 PM

Originally posted by rahuldevnath View Post

Point to be noted that I have started ripping my bike recently, and I could never cross 8K ever on this bike! Though it has touched 140Kmph on Speedo.

Dont know how your bike touches 140 at 8K RPM

Mine does 138 Kmph at 9k RPM. Even my friend's does the same. but it does go beyond 10K in other gears.
Not tried beyond 9k in 5th gear.

At 8K bike should do around 125-130.

I think its just a fault in RPM meter not going beyond 8K .
I had this problem twice (which got corrected itself in a day) . RPM meter was at 0K instead of 2k (Bike was running at that time)

**ritwik23** · 10-13-2009, 03:27 PM

Does ur bike hit rv limiter when u rev it in neutral?if its the prob with the tachometer then u'l come to knw by trying to do this.i have seen this type of problem on a 220 Fi where the culprit turned out to be the exhaust.check these two things and also ur sparkplugs.

**silver_falcon_46** · 10-13-2009, 03:49 PM

If your bike is able to do 140 its a clear indication that its a problem with your speedo and not your engine. If the bike is limited to 8k it will not touch 140. Thats for sure.

The nut being tight does not mean your tappets are tight. Check the play of the tappets. I'm so sure its not your tappets. Its the speedo. The extra time required to go from 7.5K to 8k is the fault. It should be going above 9k. So it works perfectly till 7.5k and then works abnormally.

**abhijeet080808** · 10-13-2009, 05:17 PM

Originally posted by rahuldevnath View Post

Thanks Abhi for the detailed procedure. I Tried, it seems at least with a spanner, the nut does not rotate at all. I didn't try extreme force either. Does the nut being absolute tight means, the tappets are tight?

I think I will take to AutoService one of theses days.

You will need a ring spanner. Normal ones will slip. That nut holds the tappet adjuster thing in a particular position. It should be tight.

And, the Fastest Indian should do a lot more than 140kmph, at least on the speedo!

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HELP: 220 Dtsi RPM limited to 8K

HELP: 220 Dtsi RPM limited to 8K

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