The cylinder kit in my bike was never rebored it went all the till 1.75 lakh kms without a single work in engine and gear box . The cylinder kit costs me around 2600 rs including all the piston ,rings etc but without valves which I got from the service center didnt fit and I had to go for another from outside shop.

That's excellent! I've seen and heard the same from more than a few fiero owners.You could have re-bored it then,like i had advised you a while back.

My mech and I had a discussion before buying the cylinder kit , he asked me whether I would reach high speeds and when I replied yes sometimes,then he advised me to go for a new kit don't know the logic behind it .

The highlighted portions lack just that,logic.No wonder this mech is so 'Attached' to you .Bro,do yourself a favor and stay away from going for the RTR bore kit etc till this mech is attached to you.

Common buddy what is the gain for him in getting me a new kit rather than rebore? he cant use the old one in any other bike cause in our little town there are a very low number of fieros . but yes his suggestion lacks logic but again he had done a wonderful job with my boy .( Even if he gets a 1000 rs more from me I wont be bothered if the final work is good .)

I donno about your town or your mech bro,but such bores changed at showrooms etc ,get honing done,add a over-sized piston kit and a wash later.Voila!! a new fiero bore-kit! I've seen such bores heaped like coconuts at piston sales shop,when i inquired,he admitted that mechs buy those along with piston kits,wonder why? and the price he asked for it was 250 bucks for the fiero bore and add another 400 bucks for a over-sized piston kit and you imagine the rest.I had mentioned about this to Psr as well in a pm.

hmmm you make me think again and pls I had edited my post before your post pls reply

About 180 conversion I actually got the confidence only after he finished my bike work and rode it for about 400kms .

And do me one favor what are the things should be changed for 180 conversion (every bits and pieces in detail ) pleaseee.

Think about it,even the showrooms buy spares from spare shops/distributors etc.That's why they take time to procure.One way to be on the safer side is to ask the showroom stores guy to show you the order placed ,reflected in the TVS spares order status software.This can happen only if you know them.Otherwise if the spares are hard to come by,then such re-worked spares,or worse spurious ones can even end up with the showrooms.That's why i always advise my friends to go for current model's parts and not bother too much about keeping things stock.There are lots of spurious fiero cams,just like other bike's for example ,which are fabricated in china and a guy here experienced the damage such crucial parts can do to a person's peace of mind leave alone the engine.

Parts needed :-
RTR bore-kit.
RTR cam chain tensioner.
RTR head assembly(i wouldn't recommend you to go for the fiero head matching,because i doubt your mech's confidence) .

Edit: The guy who ended up spending 10k was N Aditya,5k with the local mech who ruined the engine with a chinese cam and then another 5k i think to set things right by getting the original fiero cam along with a re-bore,which the local mech had also supposedly done.His engine's piston was seizing up due to wrong cam and other shoddy engine work done.

A Fiero takes much abuse in it's stride and continues to work, unlike the later models of engine....while a 180~195cc conversion on a Fiero is possible, the mech working on the project should have his basics right...Safer way to go for 180cc upgrade will be to go for the RTR 180 bore+piston kit + top Head with Valves. This is a comparatively expensive proposal...otherwise, the Stock Fiero bore can be bored to RTR 180 piston size, and Fiero Top Head squish area corrected to suit 180cc bore dia....
Here is a picture to help...note the champhering of the inner edges in a RTR bore to match the dia of increased bore size.

Bang on target thats what I was also thinking even if I have to revert to stock it can be done with the current setup. So it is again a bolt on job no need to change anything with electricals and all.
what could be the cost of the three parts approx ?

but I have a urge to make a tacho working in my bike lets see! then it needs a tci unit with ignition coil of RTR isnt it ?

If I ever dream to get a 180 conversion in my town that is the only way .

BTW. I have internet connection only after 10am till 8.30 pm so couldn't reply yesterday sorry.

Bro don't hurry into things,that's my advise.Your girl's got a new cylinder,so enjoy her and in the meanwhile you can search for info on how to go about getting a used RTR head.Enjoy her.Forget RTR bore kit etc for now.Stock fiero is a fantastic performer as it is.

OK buddy accepting your advise , the reason I again thought of rtr bore is the way my bike feels after the engine work I got so much confidence that my mech is capable of doing things right with rtr bore but I should be able to explain the details to him, so for that I should know all the details first about rtr conversion ( may be he is not that educated so some ill logical comments forgive him . )

+1.

@maxx

If you feel your bike is good, why should you worry about it? Its every biker's dream to have more power. Unless you are racing with it, whatever that satisfies you is enough.(I have downgraded from a 20bhp torque machine to a 13.8bhp commuter. The happiest thing is, my wallet is heavier than before). 1.75 lakh kms is really impressive. I wouldn't have pushed it more than 50k, even if it runs well. Hope you reworked the crank as well. If you go for the 180 cc upgrade, pls do so. The linear motion of the piston is converted into rotation by the crank. It takes very hard beating and it is always advised to rework the crank for every second oversize.

1..Bike feels good really! so operation postponed with the advice from two seniors
2. I was really surprised when you went for gs150 how is the bike feeling ? any ownership review ?
3. 1.75 lakh kms! really buddy I dont know that a engine work will be this much easy I really thought it like a rocket science.
4 . What should be done with the crank you mean it should be changed ?

1) Gixxer and Nano are the seniors when it comes to Fiero. I have very little on-road experience with it.
2) Its a suzuki, it will be good. Though not satisfied with its power, highly satisfied with its comfort and braking. Braking is very good and engine cruises effortlessly. Top speed achieved=117, 5th gear. 6th gear is virtually useless at speeds greater than 90.
3) You have worked only the upper part, which is not a big deal. The entire engine is not a big deal either. Fiero engines are simple and sweet. 2 strokes are much easier. It just takes 30 mins to reassemble a fully reworked 2 stroke engine(Yamaha rx135).
4) The crank has a connecting rod and a needle bearing in it. Upon usage, this bearing wears and the connecting rod starts shaking. Though left-right shake is not an issue, up-down shake must not be there. It will cause the connecting rod to bend, resulting in loss of performance and reliability. A crank seizure is more severe than piston seizure. If it happens at high revs, the piston will break into pieces and you know what will happen. I hope it doesn't happen in your ride. Though it is a Suzuki, there are chances. Never take a chance when you can avoid it.