Sorry to hear that buddy and Thank's for the kind word's outworldly maniacWhizzkid_ram has given me his mech's number already.I trusted the castrol official who talked so nicely to bring my bike all the way to chennai.World class service my ass.

Thanks sarvajit sir i will remain calm and do everything possible to get my ride back in shape.

Thank you too buddy. Well this is the case in our place . People are really dumb .It will take actually some more years for people to learn actual things . And yeah all big names are just names. Very very few guys know to diagnose problems and know their solutions .

Don't worry buddy, its not something that can spoil your engine so soon. Engines are made to take much much much more than that!
Get the tappets&timing (if applicable) adjusted well, I don't see why your problems shouldn't be solved.
As soon as the mech claims he is done, fire up&check-at the last service, I got my R15's tappets adjusted thrice till the right setting (&sound) were achieved.
Speaking of tappets, my Fiero F2 sounds like a temple bell during arti now!

I hope most of us are aware that TAPPETS ARE TO BE ADJUSTED WHEN ENGINE IS COLD, proper setting will never pop up the probelm again unless engine is taken to severe abuse.

@Sarban
Its not nessecary tha Big service centers do that job correctly, my experience says that even a smaller ones have better competency as compared to the bigger ones. Try another SVC, ma be that would be helpfull.

Update i kick started the bike in the morning it started with a single kick.As the engine was cold zzzzzzzz kinda noise was coming from the head.So kept the bike below 5000RPM.CBZ guy's let the bike cool for a some time.Then he started adjusting the tappet he showed me step by step what he was doing i did not understand much.He aligned the T mark with the marker on the thread(i clearly saw this one).Then he told me to to shake and feel the movement of the rocker arm(i think that's the name he used).He said one has small movement while the other has a little bit more play.I could not feel this but i could certainly feel the play.

In is for fuel air mixture while the Ex is for exhaust gas.He said the exhaust valve need's more mm than IN.He said gas going out more heat blah blah i did not understand a thing yet i was nodding like i knew everything.

Then he started the bike with the head open i was like WTF are you doing.....He said i need to watch this a few second's later oil was coming from the top .As the lid was not in its place the oil was flowing here and there.After about 5-10 sec. he switched it off.The motul that i saw was greenish in color looked like jelly.He explained where the oil goes and the importance of warming the engine again blah blah blah.

I asked him about how much gap is their he said its IN = 0.8 EX = 0.10.He said he is gonna set it to IN = 0.7 EX = 0.8 i said the manual say's IN =0.8
EX = 0.12.He said that's how much Castrol manual say's for the CBZ.I thought what if castrol manual was for the OLD cbz not the xtreme and told him to show his manual i checked it for Unicorn as both have the same engine.For Unicorn the gap is the same as our Xtreme that is IN = 0.8 EX= 0.12.So i pointed that and told him to set tha same gap.He said it would be too loose and i will hear the irritating noise AGAIN .He set it to 0.7/0.8 said it would not damage the engine and he instructed me to get the tappet checked @ every service if it has become tight(he said it will) .

Now the zzzzzz sound is minimized but it's their.... i have to listen carefully.Upto 60KM/hr no valve noise after that as i increase the throttle i can distinctly hear the valve noise.Its more noticeable when i am decelerating from 90Km/hr-60Km/r.When the needle reaches 60 the noise stop's.

@Riaz only one SC here that too more than 30Kms away .

@sarvajit i have no choice but to go to some local mech if the CBZ guy's get it wrong again

My Achiever has following valve clearence,
Intake : 0.08mm
Exhaust : 0.12mm

All your figures are confusing/incorrect

You are correct its 0.08 not 0.8 what about noise .

Dude, you should have told Castrol to keep their manual to themselves. Did Castrol make the bike or HH??? You should have made them set the IN = 0.08 mm, EX = 0.12 mm ONLY! And not after "cooling for sometime"! It has to be at room temp. And "getting tappet checked at every service" is not acceptable. It should be set perfectly once and forgotten about for quite sometime.

I do not blame them it's me who is at fault.Castrol bike zone suck's just like their oil.I wasted petrol worth Rs 900 to just attend this fault.

So if the tappet is set to what the manual say's no noise should be coming from the engine right.

guys update from me .. gave bike for servicing at hh sc .. last time the mech fixed my brake tak tak prob this time he tightened the brakes too much and the prob has cropped up again ..

flushed the engine using cyclone flush and changed to petronas sprinta 5000 10w40 .. have found difference .. better acceleration and slightly smoother gear shift .. hope it will get better after a few 100 km's

How much does the flush cost?

^^Will flushing the engine like that harm the engine in anyway?

no,infact i flush my engine at every alternate oil change.U should see the colour of the oil while draining after using the flush