Thanks bro.
Yes, its the dust.

@PSR @ALL

The last couple of days have been busy and spent most of the 3 days searching for banjo bolts with diesel spares dealers.Then finally took Mr Murthy's advise to get suggestions for this mod from Mr Venugopal.That guy is a "engine-hacker" alright. He was surprised as to what's the need for a oil-cooler as the 200cc mods don't have the need for one,then i convinced him that i am doing this for the sake of modifications and nothing else.There was his friend Mr Srinivas too ,who both have designed and fabricated the parts needed for the V-Twin fiero,superchargers of various kinds for the fiero etc from scratch.
They told me this oil cooler mod has been done by them and it's not a big deal.They actually told me that i should have gone for the ZMR oil-cooler(you were right abhi about it being bigger).They had put a a ZMR oil cooler and had found that it cooled the oil by about 10 deg c more than the pulsar one.ZMR needs it as it has a full fairing for a air-cooled engine.
Then took their guidance and found the 8 by 50mm smooth thread bolts,which incidentally are made from TVS and cost 30 bucks each.The interesting thing is the banjo bolts are not easily available and they cost a bomb!!The RTR/fiero single banjo bolt cost me 100 bucks including the washers or 200 bucks for the set of 3!!
After this,i took the bolts to the lathe guy they recommended and got the 3 8/50mm bolts converted to double banjo bolts and the labor for doing this was 210 bucks.So ,each double banjo bolt cost me 100 bucks!! The bike needs one single banjo and another double banjo bolt,but i got all the 3 bolts converted at one go.
All the banjo unions,etc are easily available at diesel spares or diesel engine overhaul areas.Finding the right 8/50mm soft thread bolts was the one which needed lot of legwork,till i got the info from Mr Venugopal that is.
The lathe guy has done wonderful work in converting the bolts to double banjo ones.

PS: I had bought 10/50 mm hard thread bolts as a last alternative to convert them to 8/50mm soft thread double banjo bolts.So conversions are easily done and not a big deal at all.

Though frustrating in the beginning, must be rewarding and happy when you got things done ....what a relief, so now fitting and running is the only thing left to do.
Good Luck

Yeah,now because of the leg-work i did the last few days,i know exactly where to go to find these spares.
The thing is, i spent about a hour each the last couple of days at Mr Venugopal and Mr Srinivas's work place picking their brains. Thought i'd mention this to you as you had told me you were interested in the things they've done.

Hey guys whats up??
I am about to change the front disc brake pads, but the ASS says they are in shortage!! And therefore he has placed the order for them.. is it the same in ur cities too??

Yes its the same here too. My bike's brake pads are worn out too-last to last time the disc plate was changed&I didn't wanna ruin it by going for local ones. The funny thing is SVC guys are offering 'local made' pads too!
Now I understand why my clutch plates are wearing out every 12-14K kms.!
Anyway, I doubt if I'm gonna attend to any of the problems in my bike as I'm selling off soon.
Enjoying my R15&triple digit speeds every day.

Can someone help me sort the clutch issue ???
The damm springs, clutch as well as pressure plates are all new, still it isn't what i am looking for !!

The rear suspensions which are new, doesn't seem very new after just 1 week, they are OEM though.
Besides, i need to change my front right fork pipe, the dealer is asking for 1900 bucks for 1 pipe (without anything else) for the original one that is.

He says he can source local one's at 1200 bucks a pair too, any comments ??

ya i know!! my friend who has the same bike, has ordered a new set od crankshaft, piston and cam chain, its been over a month that some parts have not arrived as yet!! he is going for a complete engine overhaul, so since all news parts have not arrived, he cant go ahead with it... they say it will take another 10 days to come...

ok guyz i have one question, Is there any special type of chain lubricating oil to oil the chain?? i hv removed my chain cover and i have to oil my chain every week.. so i dont like to go the SVC and oil the chain everytime for free... and which type of oil do they use? the discarded engine oil or some other type of oil?? because i was thinking of keeping the oil at home and lubricate it whenever i want to..

Castrol SAE90 gear oil .

Oh yes, I have some comments!
Same 2 probs. in my F2 as well.

1)Clutch plates
Clutch plates have been wearing out every 12-14K kms.&still even after changing I don't get the 'feel' back in the bike. Moreover there is a rubbing sound which is very prominent in 2nd gear, which is due to the clutch bearing. Any ideas on this?
Like Anand says, I think they are replacing with local plates (my mech. confirmed this).
I was thinking of getting the entire set replaced, like clutch plates, pressure plates (what are metal plates?), springs etc.
Could you please post prices of OEM clutch parts&is it also available as a kit?

2) Fork inner tubes
Now, coming to your fork pipe-ditto problem in my case too, the RHS inner tube has scoring marks&keeps rupturing the oil seal. I think its better we change the fork inner tubes as a set+springs&oil seals obviously need to be changed as well.
I have a quotation (TVS ASC) of Rs.2100 for set of inner tubes but no availability here in Hyderabad. Anand&Abhi are trying for it in Bangalore. I would advise against the local ones.
I got another quotation (again TVS ASC) wherein he couldn't source the inner tubes but had the entire fork assembly for Rs.2500 per side. I find it way to expensive&unnecessary since the outer legs are not damaged by an accident or otherwise.

3) OEM disc pads
I got my disc plate, pads&oil replaced at 50K kms. 58K kms. on the odo now (speedo cable gone)&they are worn out completely. Need OEM pads but again no stock here. Can you help me with this as I'm coming to Pune next month I can pick it up or else you can ship it across? Anand&Abhi have managed to find one set for me-that will do for the timebeing, I'll get the bike serviced.
I would like to stock up on atleast 3-4 sets so that I don't need to go hunting for disc pads everytime.

@psr, @All: I have decided not to sell my bike as I'm in no position to buy a new vehicle. With your help, I would like to get the probs. solved&use it for longer.
I don't even find it worth investing 60-65K (interest inclusive) on a scoot by selling my bike for 12-13K. It has life left in it&wants to be with me.

Well, clutch is the only unsatisfactory feel i get from the bike.
Hell, i feel the clutches of even splendor's better than this one, again due to the plates i feel.
The plates are available at OEM TVS blue case with seal, also the pressure plates both of them would settle you down to roughly 420 ~ 480 bucks.
But i again strongly recommend that its useless to go for them, all it would do is avoid slipping until the first few weeks, and give you a good pull until 1 month MAX, after that its all the same.
As good as the cheap local ones.

That rubbing noise ?
Are you talking about the khaat sound that comes when you try to shift ?
i had this problem before the 180 bore kit, and it never happened again, so haven't bothered about it at all.
But having ridden the stock fiero once in a while, this problem does bring back old memories, i think its not much to do with the clutch bearings though, it feels more like a gearbox dog-clutch issue.
I could be wrong.

However, the bore kit will be a good solution to the problem i believe.

Well, the price mentioned by your ASC guy is very reasonable, in my case, the pipe alone is for 1900 bucks EACH, thats 3800 for a pair without the damm springs and seals.
But he says that if i really want it he would source it in a week.
Too much of pain on the pocket, i would rather buy a ktm 200's inverted fork set with disk and stuff with this money, another 2000 would settle me down with the rims too (all from junk though).
Besides in my recent visit to a junkyard, i saw amazing product range of ktm 200, the wheels, disk, tyre, fork set, fuel tank, headlamp, everything is available, and this bike hasn't even launched yet....

coming back to the fork thing, i think its too much of money that these guys are asking for, i guess I'd rather wait for the other one to get damaged too and then work on a pair instead.
How bad can it get ??
Atleast I'll buy time to fill the pockets again.

However as far as the parts are concerned, the ATUL guy near Vishal's house can source almost everything, he has all the stuff and can bring in more in a short span of time, I've seen people coming to him from Surat, Pune, Nasik, etc in taxis and buying parts in a lot.

Also this guy can source Fiero's Japanese metal clutch plates too, for somewhere around 2000 bucks, but my mech says that I wouldn't be happy with that too hence DO NOT go for it.

Yes, i can do that easily, the pads will cost you around 400 bucks (max) and are available.
I brought it at my first ever visit to this dealer guy, He has a lot of them in stock so sourcing it isn't a big problem.
Besides, i would recommend you to go for the complete brake overhaul, I haven't seen it personally as i wasn't at the garage when my mech did that but he said that he replaced something (maybe a valve) in the master cylinder and changed the oil, pads and related stuff, and believe it or not, this bike can OUTBREAK a ZMR with twin disks, and the best part is that the braking stability has improved a lot under hard braking because of the handlebar.

However my disk and the calipers are all 66k kms old, never changed them even once.

Well, that's what i did even after having a thinner wallet.
But trust me dude, its worth working on this bike and using it, rather than selling it, no matter how much money you spend on it to fix it, its all worth it....

@NANOtechnology:
Yes, the probs. with the clutch are slippage&the rubbing sound is not while shifting gears but while running in low speeds like 2nd gear.
What is this dog clutch? Is it part of the clutch kit?
If I buy entire clutch kit what all parts does it contain?
The metal plates of Fiero will not be compatible to Fiero F2.
The disc has been overhauled&I'm satisfied with the braking after replacing the plate. Only pads needed. Please find out-the price here is Rs.290&as I said, I would like to stock up on pads for atleast 20-25K kms. more.
The engine is still stock&running fine, so no plan of upgrades yet. No worries on that front if the situation arises too, as engine spares are cheapest&easiest to get!

@NANO..... dude did u just mention that the disc pads are available on the spot in ur SVC?? mind if u courier me a set or 2?????

For me too-atleast 3 sets.