Re: Bajaj CT100B

Hi, checked using the fuel tester bottle as that was the only reliable way of checking and found out I am Getting 65Kmpl. About the sprocket change I did not have any luck as most of the sprockets are not a direct fit so dropped that plan for now. Now about the vibrations from the bike I could not find any rubber dampners as such, I am already using a handlebar with weights from that of a pulsar. I did change the exhaust on the bike to a free flow one and then while riding at even 40, 50, 60 kmph I don't feel any vibration so I am assuming the vibration is being caused due to the resonance from the stock exhaust, poor design maybe. Lastly about the petrol smell all the screws were tight enough and the o rings were intact so I assume the smell I feel is quite normal maybe.

Re: Bajaj CT100B

Met with my co-rider after a long break and got the rest of the photo's so I'm posting a few of the CT100B along with cyclocomputer reading of maximum distance covered in a day and maximum speed recorded during the Golden Quadrilateral run.

• As you can see, I packed super light, didn't even take my usual tool kit, managed to change oil by the road side using tools that came with the motorcycle, Bajaj has won me on this front as there are tools provided which can even be used to take the wheels off the bike which is a boon when it comes to motorcycles with tubed tires.

• Couldn't resist as Puri is famous among motorcycle enthusiasts from the South of India thanks to movie-star Dulquer Salman and his movie Neelakasham Pachakadal Chuvanna Bhoomi (English: Blue Sky, Green Sea, Red Earth), a must watch if you ask me!

• The longest covered in a day, was tiresome but we had to bite the Bullet before it bit us!

• First time experiencing the expressway!

• This is the highest ever recorded on the CT100B, the speedo indicated a figure between 115~120 kmph and the funny thing being that these were normal cruising speeds, guess this is why seasoned motorcyclists always jump at the road less traveled.

• Finally the CT100B in all her glory along with the Bullet 500 and our India Gate, New Delhi.

• Off all the milestones, this ones our favorite! DEOGARH FTW!

• A dream project indeed! Can't wait to try out the other two major networks on the CT100B!

• This one was snapped at under 200 km's to home, hope to ride the CT100B farther next time, breaking more boundaries along the way!

• The motorcycle has covered around 20,000 km's on her first birthday and I believe that this is definitely going to be the motorcycle I get to ride till the odometer resets to '0', Fingers crossed!

Re: Bajaj CT100B

Would anyone be able to provide me with the tappet clearances for the CT100B?


I've tried a lot to hunt for the CT100B's workshop manual but I'm out of luck, do share the same if anyone here has a copy.

Bajaj CT100B

H4 Conversion Completed!

Sourced a Lumax H4 Dome made for the "Hero Honda CD Dawn/Ambition"



Got an OEM "Hero Honda" H4 connector as well.



Had to DIY a bit to make sure things were plug and play, which was a bit of a pain considering that my soldering skills suck.

P.S. Do let me know if anyone would require a DIY guide, asking as I had to do a bit of trial and error due to no specific guides available online.



Got myself a "Osram Silverstar HS1 35/35"



Had played around with the stock H4 temporarily borrowed from my Zen, as it was a 60/55 I somehow ended up blowing my brake light, got it replaced with a LED unit gifted by a friend who ensured me that it won't blow out due to brake lighting being DC, though I'm still a bit skeptical when it comes to the park current.



All is well for now, only downside is that the stock Beam Adjuster had to be removed as it was not compatible with the new headlight unit, but that won't be much of an issue as most classic bikes don't have a beam adjuster and the beam height is adjusted by tilting the unit manually.

Next major overhaul is roughly 3.4k km's away. Fingers crossed!

Cheers,
A.P.

Re: Bajaj CT100B

Kudos on your ride! I own a kawa bajaj boxer, the prev version of ct 100. After 16 years (give or take a couple years) and definitely more than 50k something kms (the odo decided to take a break and we thought it deserved it a few years back), this baby still runs like a dream. She hasn't seen the service center after the 3rd free service bajaj provided until, 3 years ago when the bike was officially handed over to me by my dad. The first thing I did was take it to an authorized dealership and get it completely checked. I was quite pissed when the woman at the front desk was smirking and passing comments about my bike. I believe that the boxer is the next best thing Bajaj made after the Chetak, tbh, and that's exactly what i told her. Next thing i did was swap the handlebar and a few other cosmetic changes, after the making sure that the needful was done at the dealership. I'm sure I'm never gonna part ways with her unless I can't help it. That's the kind of motorcycle she is. A keeper.

Re: Bajaj CT100B

Hey guys,

Have done a DIY Battery Delete on my CT100B, do check it out.

DIY: Motorcycle Battery Eliminator

Re: Bajaj CT100B

Hello to Fellow ct100 walas,
Hope its ok to join in with my two bits. Bought my CT100 KS on the 31st of May, so it's some 20 odd days old now, and have clocked 438 km thus far. I had seen this thread before my purchase, and yes the reports did influence the choice; Having said that however, I am almost sheepish in the company of such experienced and die hard users of the model. The reason I bought it -apart from being a fine budget product - was that I am seeing this bike as a way of getting back into riding on two wheels, after a very long gap of 20 something years. I don't really see myself as a long term user, would just like to get back my road sense, driving fitness and self confidence before going in for anything more ambitious. Most of the riding has been city stop and start, with two spells on NICE road where I touched 60 kmph, another 60 km run on a country road. I am liking the bike very much, it vibrates much less than a Enfield, the night light is decent enough, it is high on maneuverability and best of all it is non intimidating. A fifty km stretch does however get me tired, but that my aging body, not the bike alone. So also I cant take a pillion confidently, the bike swerves a bit, but that again is probably me. On the whole I am happy with the bike, its great to get back on two wheels again, and I think I made a good decision fir the purpose I had in mind.

Re: Bajaj CT100B


Engine-Head Cleaning at 16,000 km

Around 15,000 km, my bike started stopping while idle-ing. After few 100km more then it started shutting off while in 1st-2nd gear at lower speed of 10 kmph. Then I noticed the spark plug has gone black, I went and bought new one from ASC (same one mentioned in the manual) but there was no benefit. Then I took it to Varun Bajaj in Kondapur (Hyd). There the gu increased the RPM to max and then I noticed black smoke coming out. He told me the head (that means engine-head) has carbon deposit and it needs cleaning and it will take 2 days and cost 1500-/ . I asked around and all outside non-ASC mechanics and they were asking for keeping the bike for few hours for full check-up. Varun Bajaj has good reviews on Quora, so I gave it there. They took 3 days to get it done and handed me a bill of 3000 approximately. I was shocked. I bought the bike because I thought it was low-maintenance but then it has been only 2 years and I had to shell out 3K for engine. Best part is they really cleaned the head because I don't see any smoke coming out at all now. Worst part is, it still shuts off. Here is the bill breakup they told me:

1. Labor = 700/-
2. Oil change = 370/- (I told them to not to change the oil because I got it serviced at 15K but they still did )
3. Gaskets + other spare parts (he told me all the names, 4-5 different types, which I forgot = 410/-
4. Engine head Cleaning + Silencer Cleaning = 1500/-

Re: Bajaj CT100B

Sad to say this but you've been royally duped by the SVC.

1. Decarbonisation is just another scam when it comes to 4T motors, having covered roughly 6k km's more than your motorcycle mine is running fine without any such services being done, only issue per say is that the valve setting is off clearance which is typical at this mileage, adjusting that would cost me under 50/- for consumables(most people don't even bother to change the O'rings).

2. As understood from the picture of your spark plug, your motorcycle has been running extremely rich, here's mine(this is after covering 10k km's in 2 months, in which 8k km's was ridden at WOT around the country) for comparison;



The reason for the same can be due to the following;

Clogged Air Filter, can cause smoke at high RPM's, motorcycle will fail to idle properly and spark plug would also be fried.


Rich AFR, a stuck choke cable is enough for the motorcycle to not idle properly, emit smoke at high RPM's and fry the spark plug.


Improper Combustion due to improper firing, the stator connector if short(has happened once for me) would cause the motorcycle to miss fires and emit smoke at high RPM's also resulting in a fried spark plug.

Re: Bajaj CT100B

.. well, my roommate has 60K on odo (Hero Achiever) and housemate (Honda) has 40K on odo and of course, no smoke problem. I will get the Valve setting checked from somewhere outside. Only problem is they ask you to leave the bike and then of course, it is INDIA, they can replace any parts.

It is definitely not running rich because the screw near carburettor which controls RPM was set to the lowest possible setting, below which bike will just refuse to start and only last week after I paid 3K bill I have made it run very rich (1.5 turns of the screw) because it keeps on shutting off.

Air Filter was changed at 10K. So I doubt that. Any links to more info for stator connector problem. I just replaced my battery after 2 years, another 1000/- but this was good experience, at least horn etc are working great now.

UPDATE: I noticed one strange thing, bike does not shut-off at idle when it is started from cold. It starts shutting-off only when engine gets hotter, lets say I ride for 5 km or I keep at idle for more than 15-20 min. (This time I gave 4 hours of gap in 2 rides to cool it down. Then of course on first start it did not shut off but when it got hotter it started shutting-off ). Air-Filter I guess.

Re: Bajaj CT100B

Once again, your motorcycle is running crazy rich, which is evident from your spark plug, also by the way your motorcycle is shutting down, as a motorcycle running rich fails to idle once it reaches operating temperatures, the opposite to this is when you're running lean and your idle starts to climb higher as the motorcycle gets warmer.

There are two screws near the carburetor, one near the fuel line and one near the center, the one near the fuel line is the one that controls the AFR whereas the bigger screw i.e the bigger one is the idle screw, I'm presuming that you've been working on the idle screw, it doesn't have an impact on AFR it just affects the idle RPM.

Just for an FYI, here's a post of my motorcycle facing the stator connector shorting issue, the post after shows the remedial measures I've taken to resolve the issue;

Bajaj CT100B - Utilitarianism Redefined!

Also to add, running rich has another ill effect called "Bore Wash", this is the phenomenon where the film of oil surrounding the cylinder wall gets washed off due to an overly rich AFR as a result of which cylinder-piston ring friction increases wearing down both the piston rings as well as the cylinder wall, worst case scenario the motor might seize if ridden far and hard in this condition.

Re: Bajaj CT100B

you are correct. I was setting the idle RPM screw. Today I set up the AFR screw (just like you said, it is smaller in size) and I kept it on lowest possible setting and from there increased it to where bike is running in a relaxed manner. Guess what, where it used to shut-off every time I stop, now it has shut off only once so far in a 10 km ride. I still have 15 days period from the time I paid that 3K bill. In this 15 days period, I can get tappet clearance and air-filter done for free because they did not solve my problem. One clarification, if I would not have cleaned engine head and silencer then still smoke would have stopped coming out from silencer ? They told me carbon is deposited inside engine head and will not go till we open and clean, is that true ?

I have to go to mechanic to get the seat opened and will get it greased or how about covering it in a polythene-cover ?

I am a member of few whatsapp biker groups and read online a lot too but no one mentioned the AFR screw. Everyone was talking only about one screw, idle RPM. Only you mentioned, and then I have read your eliminating battery thread and your LED conversion thread for CT100B too. How you know so much about bikes ?

Re: Bajaj CT100B

The question is why your motorcycle started to run rich only recently without the AFR not being adjusted? So rather than going ahead with adjusting the AFR you could've diagnosed other causes.

Anyway since you've already changed the AFR setting I would suggest that you replace all consumables i.e SP, AF etc and the reset AFR from scratch using the conventional carburetor tuning technique shared by [MENTION=28527]sibun[/MENTION], you can ignore the SAI disabling part as our BS3 CT00B doesn't come with SAI system. And since the CT100B lacks a tachometer you'd have to use your hearing to determine the RPM rise and drop. Once set you should make sure to note fiddle with the carburetors settings again cause if something doesn't run right then the cause being AFR tuning is unlikely as there are many other factors that could be the cause.

Decarbonizing a 4T motorcycle engine is a scam, unlike a 2T motor the 4T motor doesn't burn oil along with the fuel. But there are carbon deposits being formed at a slower rate but they would not cause any harm in fact the minimal carbon helps to cover the minor cracks that are formed in the cylinder wall/head. So what happens to the excess carbon deposit? Well, when you accelerate hard the carbon deposit burns off on its own just like that, hence why you'll notice little smoke when revving a motor that has been ridden slow for long.

Now another factor to consider is that your motors squish(space between piston crown and head at TDC) area is calculated to precision, and having a mechanic open your head and forcibly scrape it would drastically affect your performance and engine life.

I would recommend you carry out the tappet adjustment yourself after getting the valve clearances from the SVC, also do share them here as I'm yet to get them.

Here's an only DIY we made for my ZMA, the process is more or less the same;

ZMA Tappet Setting for Beginners

Don't cover it, a classmate did the same on his first gen Kawasaki 4S Champion(Similar Kawasaki motor as the CT100B) and what happened was that during cold climates the stator connector started shorting again due to condensed vapor.

I'm cheap bro, cant afford to pay SVC a premium to fix my motorcycle especially now since I'm jobless. So I manage to break,fix and learn on my own.

The Battery Delete saved me close to 1000/- for replacing the battery as a capacitor costs roughly around 50/-.

Converting HL to H4 makes sure that bulbs can easily be sourced and is overall a cheaper alternative in the long-run as H4 sealed beams are cheap to replace, even an imported Hella costs only 400.

One advantage of owning a CT100B is that you get a wonderfully reliable DIY friendly machine, which makes me honestly wonder why anyone who'd be interested in covering some serious miles would buy any other motorcycle, cause on the long run all that matters is how many km's you're able to reliably cover, doesn't matter if you spend 15,00,000/- on a superbike and it breaks down when ridden hard under challenging conditions and that too even before covering some decent mileage figures.

Re: Bajaj CT100B

Motorcycle started stopping a bit before 3rd service. I told this to ASC in Habsiguda and first I thought they increased the idle RPM but now I think they increased the fuel ratio instead because bike started stopping more and more after the 3rd service. Now I have put it the AFR back and it is stopping sometimes, not all the time, just like it was before 3rd service.


AF = Air Filter
SP = Spark Plug (changed 2 weeks ago)
SAI ?

and can you post a link of carburettor tuning by @sibun because I can't find it on his page (https://www.xbhp.com/talkies/members/sibun.html).


I guess I burnt a hole in my pocket for nothing and called for more problems in future by letting them scrap the engine head. CT100B manual talks about 41 checks to be done at every service after 5K. Silencer drain hole and tail pipe cleaning , valve clearance, air breather tube, battery voltage and spoke tightening are few. It is INDIA, I don't think ASC mechanics check (or even aware of) what all those checks mean, they did not even bother to check tappets/valves and air filter. I have come to understand people on forums and groups know more about bikes than certified ASCs. Best bet is to find a trust-able mechanic and tell him to do all those checks mentioned in the manual.

BTW, I thought tappet adjustment and valve clearance are one and the same thing. Manual mentions it by title of "valve tappet clearance" as one sentence.


I was surprised that you had ZMR and now you prefer CT100B. Generally what the consensus is that once you go to higher torque and power then you can't come back to 100cc , you just don't feel like. Now I see your point and can gree with what you said . Guess what, I am jobless too as of now ..

Re: Bajaj CT100B

Sibun's carb tuning post.