Faced a little uncalled situation with my bike's engine last Saturday.

Premise:
Friend's wedding in Hyderabad on 13th August so planned a Pune to HYD on 12th morning. I also requested clarification on current NH9 update in Maharashtra routes thread but there weren't any replies, so decided to take the plunge and go from NH9 itself, rather than other state highway route.

Now, I started early morning at 5:30 on my year old R15S, 11,200 KM ran at the time of starting, in pristine condition. Covered 100 KMs in 1 hour 10 mins, which means I was doing good time. Because the NH65 wasn't crowded much in early morning, I was cruising at 100-115 kmph in 5th/6th gear.

On my spirited weekend rides, I usually tend to redline the engine on long highway stretches but this was an approx 600 KM ride thus I didn't want to stress the engine, so no redline in any gear whatsoever.

Things which went Kaput and how:
Now, the moment I covered 150 KMs from Pune and was smoothly going at 102-105 kmph in 5th gear, I planned to overtake a bus which was a little faster than me but was there for long and I wanted to reach Solapur before 9 AM. The engine was at 9K RPM, I blipped the throttle to increase the speed gradually, the RPM went up to 10K, I overtook the bus, the speed went upto 123 kmph, which is very normal for this bike and just when I was planning to shift up to 6th gear ...

I felt a sudden jerk from underside the right foot and on the throttle hand, probably from the engine. The RPM went down to 5K, the throttle power was lost for close to 1 second and then it all came back up to normal fine. Perplexed by this sudden behavior, I slowed down but kept riding for good 2 minutes, engaged in 6th gear but something was not normal. As I was wearing the newly bought MT Mugello, the external noises were suppressed to a very degree.

It's only when I stopped after 3-4 minutes for an inspection and realized that the engine is sounding like something has broken inside of it and the vibrations of it can be felt on the seat as well.
The sound is of - take 10 metal balls in a metal jar and then shake the jar. That bad. It didn't sound like very loose tappets but worse than that. The engine sounded like a broken auto, right from idle RPM to any RPM in any gear.

I checked for any smoke - No smoke.
Clutch operation didn't have any effect on this sound and vibrations, so I discarded the burnt clutch plates.

Now, it was 8AM and I'm basically standing on a highway's side, had to take a quick decision to either ride more 100 KMs upto Solapur and get it checked there or go back 150 KMs to Pune to my SVC and see what has happened. But in any case there was a risk of damaging the engine(more).
I decided to screw the wedding and move back to Pune before it was too late to do anything. I rode back at no more than 5K RPM, reached in 2.5 hours. All the way the engine sound kept sending shivers down my spine, but the bike kept running without overheating or anything else, good thing. No engine warning light, no high temperature light.

The bike currently is in SVC, they took the area service head to open the engine under the 2 years warranty to see what's wrong. The regular mechanic over there is a little baffled on this situation and said this is the first time he saw happening on an R15, that too this early, if it happens. He suggested it might be piston block.
I studied this exact issue of web and the root cause ranged from piston ring to cam chain tension-er to what not.

Well, they had a couple of bikes to service and I had to leave for work so I couldn't stay for another 2 hours to see that myself but I'm expecting a call soon from the regular and my trusted SVC guy there, who's taking this matter very seriously. I'm keeping my fingers crossed as well.

I'll keep updating here the progress with the RCA.

Anyone has any ideas, speculations or any suggestions?

Regards.

Any updates bro ..?? very sad news.. same problem suffered from my pulsar 220 1year back ..was riding 100-110 speed.. but the problem was one way clutch assembly..repair cost was only 250rs..

Sad to hear bro. I hope it's just a minor issue.
U said that you are in 5th gear (in 100+kmph) & then shifted to 6th to overtake. I think that's the reason behind this issues. Riding at 3 digit speed in 5th should have created more tension in engine. Once you reached 80+ kmph you should have changed to 6th. (correct me if I'm wrong guys ).
Because once we faced this problem in my friends pulser 150 for riding at max speed in low gears. Result change of clutch unit.

Update us once problem is sorted out.

I'm still due on the update because of SVC holiday today.



Update is still due.

A well broke-in R15 reaches 100+ in 5th gear with little to no stress on the engine, that's how my weekend rides are since last one year.
Can't compare it with commuting oriented P150, no disregards.

I did not shift up to overtake, 6th gear is not for that. In high rev range/higher gear either you have to stay in the same gear to utilize remaining power band or gear down, not up. If I'd be shifting up from 5th to 6th in 80 KMPH, I'd be shifting down the next moment to even accelerate if I need to overtake someone.
It's not about the speed, it's about RPM, take note. You can shift up at as low as 50 KMPH/5K RPM for 5th and 6th gear, but you'll be lugging the engine which is equally critical.

It's probably something minor I hope.

Regards.

Faced a little uncalled situation with my bike's engine last Saturday.

Premise:
Friend's wedding in Hyderabad on 13th August so planned a Pune to HYD on 12th morning. I also requested clarification on current NH9 update in Maharashtra routes thread but there weren't any replies, so decided to take the plunge and go from NH9 itself, rather than other state highway route.

Now, I started early morning at 5:30 on my year old R15S, 11,200 KM ran at the time of starting, in pristine condition. Covered 100 KMs in 1 hour 10 mins, which means I was doing good time. Because the NH65 wasn't crowded much in early morning, I was cruising at 100-115 kmph in 5th/6th gear.

On my spirited weekend rides, I usually tend to redline the engine on long highway stretches but this was an approx 600 KM ride thus I didn't want to stress the engine, so no redline in any gear whatsoever.

Things which went Kaput and how:
Now, the moment I covered 150 KMs from Pune and was smoothly going at 102-105 kmph in 5th gear, I planned to overtake a bus which was a little faster than me but was there for long and I wanted to reach Solapur before 9 AM. The engine was at 9K RPM, I blipped the throttle to increase the speed gradually, the RPM went up to 10K, I overtook the bus, the speed went upto 123 kmph, which is very normal for this bike and just when I was planning to shift up to 6th gear ...

I felt a sudden jerk from underside the right foot and on the throttle hand, probably from the engine. The RPM went down to 5K, the throttle power was lost for close to 1 second and then it all came back up to normal fine. Perplexed by this sudden behavior, I slowed down but kept riding for good 2 minutes, engaged in 6th gear but something was not normal. As I was wearing the newly bought MT Mugello, the external noises were suppressed to a very degree.

It's only when I stopped after 3-4 minutes for an inspection and realized that the engine is sounding like something has broken inside of it and the vibrations of it can be felt on the seat as well.
The sound is of - take 10 metal balls in a metal jar and then shake the jar. That bad. It didn't sound like very loose tappets but worse than that. The engine sounded like a broken auto, right from idle RPM to any RPM in any gear.

I checked for any smoke - No smoke.
Clutch operation didn't have any effect on this sound and vibrations, so I discarded the burnt clutch plates.

Now, it was 8AM and I'm basically standing on a highway's side, had to take a quick decision to either ride more 100 KMs upto Solapur and get it checked there or go back 150 KMs to Pune to my SVC and see what has happened. But in any case there was a risk of damaging the engine(more).
I decided to screw the wedding and move back to Pune before it was too late to do anything. I rode back at no more than 5K RPM, reached in 2.5 hours. All the way the engine sound kept sending shivers down my spine, but the bike kept running without overheating or anything else, good thing. No engine warning light, no high temperature light.

The bike currently is in SVC, they took the area service head to open the engine under the 2 years warranty to see what's wrong. The regular mechanic over there is a little baffled on this situation and said this is the first time he saw happening on an R15, that too this early, if it happens. He suggested it might be piston block.
I studied this exact issue of web and the root cause ranged from piston ring to cam chain tension-er to what not.

Well, they had a couple of bikes to service and I had to leave for work so I couldn't stay for another 2 hours to see that myself but I'm expecting a call soon from the regular and my trusted SVC guy there, who's taking this matter very seriously. I'm keeping my fingers crossed as well.

I'll keep updating here the progress with the RCA.

Anyone has any ideas, speculations or any suggestions?

Regards.

Any updates ?

Not yet but probably by EOD.

Thanks.

Sent from my SM-E500H using xBhp.com mobile app

Question -
Because this is a second run-in due to new parts inside the engine, I was thinking I'll need to replace the engine oil after 1000 KMs, but the svc guy suggested I won't need to as these parts won't create as much as metal debris which will call for an engine flush. However I'm kind of concerned on that matter.
If someone has any insights or views on this, please feel free to suggest, that'd help making a choice in that regard.
Thank you all for showing your concern. Ride safe.

Regards.

Thanks for the update. It seems to be like incorrect tappet adjustment causing the valve guide to fail early or it could be a factory error with a faulty guide to begin with. The reason for the seal to fail could be the excess clearance between valve stem and guide which makes it wobbly and tear of the seal. Wish Yamaha uses low oil pressure switch which can warn us in such situations and also failure of oil pump. From the pics it looks still cylinder kits are Indonesia make. Are the pistons from usha or some other make.

I'm just glad that you are ok mate. regarding the change of engine oil. when you take the bike for inspection, request the mech to open and show you the oil filter. If it sparkles in bright light (metal filings), change the oil and filter, else no need. Ride safe brother.

Guys, need your quick help.

I bought my R15S on 28th July. I was able to clock only ~700 kms so far due to work and rains. I feel the engine is now getting too hot in crawling traffic which wasn't the case during the first few 100 kms. Does it mean the engine oil should be replaced? My first service is due in 3 days and I was planning for a 120 km trip tomorrow just to add more kms. Should I go for the trip and then do the service or since the engine is getting hot should I go for the service tomorrow?

Thanks.

My suggestions will be....
1. Don't push your bike above 4k rpm or 50 kmph.
2. Give 5 min break after every 45 min ride so engine can cool down.

Guys, need your quick help.

I bought my R15S on 28th July. I was able to clock only ~700 kms so far due to work and rains. I feel the engine is now getting too hot in crawling traffic which wasn't the case during the first few 100 kms. Does it mean the engine oil should be replaced? My first service is due in 3 days and I was planning for a 120 km trip tomorrow just to add more kms. Should I go for the trip and then do the service or since the engine is getting hot should I go for the service tomorrow?

Thanks.