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**Ayson** · 12-19-2009, 09:35 PM

Hi guys. I have some reports to make.

I replaced my helmet lock / helmet holder. It cost Rs 150. The old one had to be sawed off. It had bolts whose head breaks off upon tightening. The new one has one-way screws. The mech i went to did not have the screw driver for it, but a flat one worked. He charged me Rs 20.

I filled full tanks today. The meter showed 4 bars before, and it took 14.32 l over that. The petrol kept pouring in but the level was rising so slowly! Even after it reached the brim he poured for another minute!!! Then he just stopped. I checked and it wasn't owerflowing from anywhere. That put me back by Rs 680. One warning to anyone filling full tanks. NEVER leave it on the side stand after that. Petrol will overflow. Fortunately i was away only 3-4 minutes. It flows out pretty fast, like 2 drops/s

.

And the final mistake! I broke my disc bleed nut in half! I was trying to loosen it to bleed, and half of it just came off.

Guess ill have to get the whole calliper assy. changed next time.

**abdelazeez** · 12-20-2009, 11:46 AM

Originally posted by Ayson View Post

One warning to anyone filling full tanks. NEVER leave it on the side stand after that. Petrol will overflow. Fortunately i was away only 3-4 minutes. It flows out pretty fast, like 2 drops/s

.
.

Whoa! I never thought that could happen (maybe its coz I've never filled up my tank to the full yet), but thanks for the heads up.
Cheers and keep up the good work.

**Ayson** · 02-17-2010, 04:34 PM

Head disassembly

Hello everyone, i have a new Q. Please give me guide to opening up the headlight assembly. Basicaly, i want access to the bottom of the speedo unit and headlight bulbs, and mainly the wiring inside.

Ive tried opening once before, but the problem is i dont know what order to remove the screws in. After removing the 4 screws of the speedo and the two screws below the turn indicators, im at a dead end.

Please give me the order.

**Ayson** · 02-23-2010, 11:05 AM

I have opened the head but im still not sure if i did it right.

Here is another doubt. I have noticed recently that my rear wheel is not aligned properly. The notch on the left and right do not match. I have picked a section from the service manual to help me, but some instructions are confusing. Please help.

Here is the SM instructions.

Chain Slack Adjustment :
1 Set the motorcycle upon its centre stand.
2 Rotate the rear wheel to find the position where the chain is tightest and measure the vertical movement midway between the sprockets.
3 If the drive chain is too tight or too loose, adjust it so that the chain slack will be within the standard value i.e. 25-30 mm.
4 Loosen the rear torque link nut (A) & rear brake adjusting nut (F).
5 Loosen the left and right chain adjuster lock nuts (B).
6 Loosen the axle nut (C).
7 Loosen the bearing carrier nut (D).
8 If the chain is too tight, back out the left & right chain adjusting nuts evenly & kick the wheel forward until the chain is too loose.
9 Turn both chain adjusting nuts evenly until the drive chain has the correct amount of slack. To keep the chain and wheel properly aligned, the notch (E) on the left chain adjuster should align with the same swing arm mark that the right chain adjuster notch (E) aligns with.
10 Tighten both chain adjuster lock nuts.
11 Tighten the sleeve nuts securely.
12 Center the brake panel assembly in the brake drum. This is done by tightening the axle nut lightly, spinning the wheel, and depressing the brake pedal forcefully. The partially tightened axle nut allows the brake panel assembly to center itself within the brake drum.
13 Tighten the Axle Nut
14 Tighten the torque link nut
15 Fix the snap ring
16 Adjust the correct brake play

The items marked in red are not labeled in the SM. Please help me identify them.
The bearing carrier nut has an inner nut and and outer one. Which to adjust?
Since my objective is not chain adjustment, can i skip any steps?
What SAE 90 oil should i use to lube the chain?

Please help me with the above questions. Thanks in advance.

**abhichotu.abhi** · 02-23-2010, 11:47 AM

Originally posted by Ayson View Post

I have opened the head but im still not sure if i did it right.

Here is another doubt. I have noticed recently that my rear wheel is not aligned properly. The notch on the left and right do not match. I have picked a section from the service manual to help me, but some instructions are confusing. Please help.

Here is the SM instructions.

The items marked in red are not labeled in the SM. Please help me identify them.
The bearing carrier nut has an inner nut and and outer one. Which to adjust?
Since my objective is not chain adjustment, can i skip any steps?
What SAE 90 oil should i use to lube the chain?

Please help me with the above questions. Thanks in advance.

It's hard to explain in words, post some pics. can guide then..

Why do you do this jobs yourselces, If you go to a mechanic, he will do it in 5-10rs.

**Ayson** · 02-23-2010, 07:37 PM

I was thinking of posting pics, then i forgot

. Ill post soon.

I like DIY

but more importantly:
First, im not sure if the mech. will humour me if i say "align my wheel".
Second, he may not do the entire procedure correctly. I might end up with a chain slack problem or a brake centering problem. I want the procedure in the manual to be followed fully. And i don't feel comfortable telling the mech how to do his job.

On second thought, ill see what the mech does. Ill also ask him to lube it too.

**Ayson** · 02-24-2010, 06:47 PM

Here are the pics. These are the first pics of my bike on xBhp.

I have marked the probable parts so its easier to communicate. I will post the parts clearly labelled in the SM, and also the doubtful ones. Please help me fill up the blanks.

Please see the pics in full size to see markings clearly.

Pic 1:
1 - rear torque link nut, 2 - rear brake adjusting nut, 3 - axle nut, 4 - ?, 5 - ?

Pic 2:
A - ?, B - bearing carrier nut, C - ?, D -?, E - ?

These are the parts i need to identify:
chain adjuster lock nuts, sleeve nuts, snap ring
Please read the SM instructions in this post to get a better perspective: http://www.xbhp.com/talkies/help-me/...tml#post383373

I also need to know how tight i have to make the axle nut and bearing carrier. It is just as tight as possible, or lesser? Is there any rule of thumb? And what SAE 90 oil to lube the chain with.

**revtech** · 02-25-2010, 04:00 AM

4 - nuts for the wheel mud guard.

C - nuts for chain guard.

**Ayson** · 02-25-2010, 11:22 AM

Originally posted by revtech View Post

4 - nuts for the wheel mud guard.

C - nuts for chain guard.

Thanks, but actually, i know what they are.

What i need to know is about the nuts mentioned in the SM instructions. If you read the last 3-4 posts, you'll know what im looking for. Thanx.

**DETROIT PISTON** · 02-25-2010, 12:36 PM

Originally posted by Ayson View Post

THANK YOU for so many, and quick replies.

The reason i asked for the tank capacity is to calculate my fuel efficiency. My plan was top it up so its 15l and wait for a constant red so i know its left with 3.2l then divide 11.8l by my km run. But that won't work now

. I was assuming that full was 15 and red light was at reserve which is 3.2 in the manual.
.
.
.
.
.
6 Is it possible to retrofit the UG4 tank flaps on my UG3? And if yes, any idea on aprox. cost?

Can these flaps be fitted onto the UG2 Tank or does it touch the handle bar while turning???

**revtech** · 02-25-2010, 02:15 PM

Originally posted by Ayson View Post

Thanks, but actually, i know what they are.

What i need to know is about the nuts mentioned in the SM instructions. If you read the last 3-4 posts, you'll know what im looking for. Thanx.

yeah i know whats being discussed but you left it with a ?? so thought id fill in the blanks

**Ayson** · 02-25-2010, 10:06 PM

I think i've figured out most of it, i just need to know about the "snap ring". Please help me find it.

**tanendra.gh** · 04-13-2010, 01:44 PM

Can any one help me... how to install oil cooler system to new p180ug4...

**neon** · 05-31-2010, 02:27 PM

Originally posted by abhichotu.abhi View Post

Yes you can upgrade.
Estimate cost will be 10-15K INR including alloys.
But,instead of spending so much sell your bike for 20-25K INR add 15K INR and rest finance and go for new Bike.

new bike is slightly out of the question, cauz i want buy a car for my family !!

but i dont want spend more than 8k, but i dont love or belive in alloy wheels for bikes, i told garage guy i need more performance oriented rather than a look-wise, which i like to keep stock with very lil modifications.

can anybody spread some light i have few questions?

Q1. Can a turbo be installed on a bike ? if yes .. then were to get it?
eg... http://www.metacafe.com/watch/51453/...ke_with_turbo/

Q2. How to get a Misfire aka (fire-breathing) aka anti-lag kit?
eg .... found anti-lag on cars ... http://www.youtube.com/watch?v=Zdu76oY8XU0

Q3. Neon glowing light below the bike (engine)
eg....

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