Nothing out of the ordinary, @SatSon.

1) Use the CPR8EA9 plug only. Not some fancy iridium plug which isn't compatible with the bike.
2) Change the Air Filter and the Spark Plug regularly. Every 10,000km will do well. Both combined won't cost more than Rs. 250 after all
3) Tune the carb as per Sibun's method. My mileage shot up after this in particular. The sweet spot is usually between 1.5 and 1.8 turns I guess
4) Tappets, bolded because it is extremely important. The engine seems to be very sensitive to the tappet adjustments. Stick to 0.07 for the inlet and 0.10 for the exhaust. I'll get to why not 0.08 and 0.12 in a bit.
5) Drive Chain: The people in the SVC over tighten the chain causing multiple issues ranging from tight gear shifts to a rubbing feeling near the footpegs.

Besides these, I am thinking the 15T sprocket in the front is definitely helping, as is the extra torque from the Race Concepts 165cc bore.

Now, why 0.07 and 0.10? Because, I set my tappets to 0.08 and 0.12 today, because I had new rocker arms. As soon as I started the bike, I could hear tappet noise. Called @sibun, who asked me to switch over to 0.07mm and 0.10 setting, which is what I used when I had worn out rocker arms. I set the exhaust valve to 0.10 but left the inlet as it is at 0.08.

Result?

Ridiculously loud tappet noise. I rode the bike for around 3km and the dreaded tappet noise started. Looks like I'll need to wake up at 5:30AM tomorrow only to set the tappets because if the noise for a 6km ride was intolerable, I do not want to imagine what the bike will sound like after my daily 17km one way travel.

Well, as luck would have it, the tappet noise still persists.

What bugs me now is, the rocker arms move laterally. By that I mean, supposing the arms are placed along their length facing east and West, I can move them a few mm towards the North and South.

Can't attach a video from here. Will post it tonight.
Tapatalked from Lumia 720!

There is always some very little gap sidewise in rocker arm. Not to worry about it.
U have to check ur roller play (i know these are new )may be u got faulty rocker arm

@ashwin.terminator
Please Check Carburetor and clutch plates for mileage problem. My Unicorn has lots of problems in the head dept(valves, camshaft, worn off con rod) but they never showed impact on mileage except for the unbearable sounds.
Slightly heat the screw with cigarette lighter or take it to a welder, it will come off easily.


You have to think like Dr. Gregory House MD and solve your problem.

Thanks in advance boss!

Aah, the mechanic had showed me the new rockers, they had no play. And I found a post from Sibun which says sidewise play is also ok. Sibun had suggested earlier that the cam chain tensioner could have gone kaput. But mechanic checked and said it was ok. The point is, the mechanic had set the tappets tight, during which time, there was no noise. But now, after adjusting to 0.07 and 0.10 on new rocker arms. There's noise again. And it's pretty loud!Bike has completed 30700km.This is the sequence of events that occurred. Hope the details help.1) Bike was given for service. Mechanic over tightens tappets and returns the bike. Rocker Arms and Camshaft were changed2) Mileage drops from 52(before the service) to 49(after the service)3) I set the tappets to 0.08 and 0.12 because the rocker arms are new.4) I switch on the bike only to immediately hear a rather loud tik-tik sound. (This is when the engine is cold!)5) Called the ever helpful Sibun, who had asked me to change the inlet and exhaust to 0.07 and 0.10 respectively.6) Readjusted the exhaust valve to 0.10mm. Inlet was left as is, at 0.08mm. The noise immediately after starting is gone. For now.7) Go on a 6km ride. Tappet noise is very pronounced once the engine is warm. Thought it has to do with the inlet valve.8) Wake up at 6:15AM to set the tappets this morning. Readjusted the inlet to 0.07mm and checked the exhaust valve, was at 0.10mm.9) Going to office and hear the dreaded tik-tik-tik sound again. It's still pretty loud and can be heard quite easily all the time.10) Got back home and tried to isolate the sound using a large screwdriver. Failed miserably. :PSo now, I don't know what the problem is. :/It could be the tappets, rocker arms, timing chain or the timing chain tensioner or maybe something new altogether. :/Also, I wanted to clean the slow jet yesterday. Drained the float only to find that the head of the screw to the right of this picture is rounded and the star-screwdriver has no grip whatsoever. :/[ATTACH=CONFIG]156210[/ATTACH]

As for your problem let me tell you before adjusting the tappets run the engine for 30 seconds and stop. The reason for this is that with overnight parking the tappets jams due to no oil so give wrong readings. Then adjust keeping the timing at TDC. As for the tappets keep the setting at 0.06 mm inlet and 0.10 mm exhaust and check if it is creating sound or not. As for the lateral play it is ok. Moreover after adjusting to 0.06 mm and 0.10 mm expect the engine to make a little noise when warm. Its because the bearing on getting hot make little noise. And if you want no noise then performance will suffer because clearance will be less.

Thank you @sibun. I have been refreshing this page to see if you will reply. :PSome noise is perfectly acceptable. But the noise I have been experiencing recently is maddening. I shake my head everytime I stand at a signal because the bike isn't quiet anymore. :/I will adjust them again tomorrow morning then. :P That is 4 times in 3 days! :P0.06mm is ok? No need for stock spec though the rockers are new?

No it will not create any problem. The thing is that while adjusting tappets care must be taken that no sound comes and the clearance will be such that the valve doesn't remain open when camshaft leaves the rocker. So a little bit of noise will be there as the tappets will be hammering the valves. So nothing to worry. As for the float chamber then you can use a plier and hold the screw with all your might and give a slight twist with the plier and it will open.

Ok your problem is not so difficult to solve for you to warrant change of bike or selling the bike. Also buying a bike like R15 which is technologically more complex will make you further paranoid when you face any problem with it.Ok i am listing out the details and touch the carburettor last. Ok first of all i would ask you to check your chain tension. Rotate the chain and see where the tightest portion of chain is. Then at the tightest portion adjust the chain slackness to 1.25 inch. This will make your bike smooth. Then second thing is that check your wheels are free or not. If not check the brakes and adjust as necessary. Then adjust the tappets. Set the exhaust tappets to 0.10 mm and inlet to 0.06 mm. Then check the bike if it is revving freely. If it is revving freely that means tappets are set. After the tappets are set go for adjusting the carburettor as for my method. After doing all these, check if the bike is running freely. If bike is running freely that means mileage will also be nice. Unless and until bike runs freely and revs fast you cannot get good mileage.

Hey all,

This is the first time I am posting here in Xtreme/Hunk Thread

I own a 2007 Hunk back in Chennai.. Actually, it belongs to my bro but now that he is a family man, he hardly takes out Hunk.. he uses it to drop my niece in playschool and to pick her up.. that too only at max twice a week.. I usually ask him to get it serviced before I go to Chennai for a visit so that I use it.. of course I pay for the service..

Recently I got the clutch plates and the pressure plates changed.. changed the rear tire to Ceat Gripp.. The tire gives perfect grip as the names suggests both in dry and wet road conditions..

I went back to Chennai last month end and found it wasn't used for more than a month.. the accelerator when turning the handlebar got stuck and so I got the Cable changed.. then the battery was dead so got that changed.. I got the bike checked and the mechanic said the bike is fit for long rides.. I planned to ride to Coimbatore and back the same day from Chennai..

during the ride, I noticed the bike took some long 5-10 seconds to come back to idle speed after the engine heats up say after riding for more than 30 kms.. I am sure this isn't normal as this never happened on that bike before.. I have traveled to Coimbatore on it once before and been to Pondicherry many times on it..

What could be the reason..?? Is it running lean or rich? The mileage is horrible as well.. I opened up the spark plug and the condition of it was like in the below pics..

[ATTACH=CONFIG]156251[/ATTACH]

[ATTACH=CONFIG]156252[/ATTACH]

[ATTACH=CONFIG]156253[/ATTACH]

Does the Spark Plug look alright? It was all black with out leak on it.. what could be the reason for oil marks on the spark plug?? Is the head giving up?? I did 90-120 kmph on the speedo.. Did I actually screw up the Head??

Sorry to ask such a noob question. I own a ZMR in Delhi so I am not an expert when it comes to carb'd engines.. By the way, the bike has completed 40050 kms just this month..

A pic I clicked on my way to Coimbatore on the 4th of September 2014..


[MENTION=28527]sibun[/MENTION] and [MENTION=32286]psr[/MENTION] sir.. I need your expert advice.. @others.. I hope you guys can help me out too

Thanks in Advance..

Cheers,
Reneav