Hey B7ACKTHORN, Sorry for that, I thought I had turned off the Request Access!. Just checked again and everyone should be able to download it!
Thanks!

Update :
1. Changed to Dot 5.1 brake fluid and it is definitely an improvement.
2. A new problem has arisen in the bike. The bike seems to hold on to revs without accelerator input. I can ride without accelerator input in any gear and bike steadies at around 2000 rpm in every gear, and in neutral the revs rise steadily until I turn the engine off. I plan to take it to the SVC on Monday morning but any input is surely appreciated. Thanks!

Please have check on the throttle cable play while steering the handle bar both the sides.
it should have 2-4 mm play. Over tighten throttle may increase the rpm.

after the initial warmup the rpm should settle to 1500rpm.

If you can move the handlebar full lock left and observe no fluctuations to the RPM, and unless your throttle cable isn't kinked or worn, then the issue is some where else. Perhaps, recommend you start off inspecting your throttle cable for proper free play and routing and sometimes a faulty or a cable that's on the verge of giving up can seize up inside and grab causing high RPMs. Secondly, if you have a faulty IACV idle air control valve that controls the idle, a motorised arm that adjusts the idle, your idle can go either lor or high and get stuck at that RPM, as is your case. A messed up idle screw setting too can cause these issues, but this is a probability unless someone has fiddled with the throttle body. If you don't have MIL on the dash, then start off with the throttle cable, and idle settings, perhaps that can serve as a starting point. Keep your observations posted.

Good luck.

Cheers!
VJ

Issue was with the battery as per SVC. As per SVC guy, if battery weakens, the ECU equivalent (they say it has something else, can't remember the name) will signal for increased RPMs at idle to maintain voltage or something like that such that the fuel pump keeps working properly. Early impression is problem seems resolved after battery change. Old battery lasted for only about 1.5 years which seems low to me. SVC also cleaned the O2 sensor, throttle body and injectors, replaced the air filter; and remarked other sensors were working properly.

Prior to battery change, idle screw adjustment (if it is the one near the handlebar at the beginning of accelerator cable) was done by a mechanic. This had not solved the issue. (One mechanic had also remarked that do not fiddle with accelerator cable screw in BS6 bikes, while one rider after riding my bike remarked that the throttle seemed smooth and the issue lied in ECU).
P.S. The bike was also pulling to the left which I will have to check now after battery change.
Cheers!

Wow...thats good to know that even battery voltage drop would increase the rpm......should keep in mind.

I have changed the sparkplug to Iridium one of Honda cbr 250 . Its matching one and this plug is suggested on Thailand & Indonesian performance iridium for Yamaha R15, which is of same [MR8E9]. Similar only iridium model like CR8EIX priced around 815rs. The Honda OE plug is Laser Iridium which has Platinum plated end with iridium point cost [626rs] in showroom, whereas the same NGK outside is 900rs.
Change interval from NGK chart - 1lakh miles, Honda maintenance chart - 48k kms. So far haven't noticed any difference, will keep posted. Sorry forgot to take pics before installation to post here..... the removed plug of 10k km from bike hasn't shown any carbon deposits...it was clean and had brownish shade depicting perfect full combustion,clean ecu air petrol mixture and engine is in healthier condition.


Both Gixxer 250 & CBR 250 share same Bore and Stroke, 76 X 55 ; Compression Ratio, 10.7:1

Gixxer 250 : 76.0 x 54.9 mm ; Compression Ratio, 10.7:1
difference is on the state of tuning, so I think this spark plug may not harm, will update after 1000kms of ride to for any difference in pickup,mileage etc

Suzuki recommended : - MR8E9

M - 10mmx19mmx16mm thread
R - Resistor type construction
8 - Heat Range
E - special Resistor fire end construct
9 - 0.9 mm GAP


HONDA - SIMR8A9

SI - Square tapered Iridium
M - 10mmx19mmx16mm
R - Resistor type construction
8 - Heat Range
A - special design fire end construct
9 - 0.9 mm GAP

Electronics! When the battery is on the verge of giving up, most components related to the ignition systems start to behave errandly. To your point, it justifies why the bike behaved well after a battery swap. It's not uncommon to witness this on a modern ECU-ized motorcycles, but this is a new understanding for me, and appreciate you following up with the solution, this will definitely help others.

Good luck and keep us updated.

Cheers!
VJ

If the battery has enough power to start the bike then it is good. I suspect the IACV valve not working as per spec, and getting stuck .

Once the Bike starts , even at idle the Electrical generator will be able to supply required power to run the bike...

Great that psr ji B7ACKTHORN ji ......experienced seniors on feedback and comments , I have read almost each and every comments that you posted in cbr250 forum and really hats-off your knowledge and technical expertise , its helps us a lot in troubleshooting and glad to see your response in this section of gixxer 250....thanks to both of you Thalaiva !

It is Feedback and knowledge shared by the many Xbhpians that enable us to put together a possible solution...

Michelin Road 5 Update after 5000Kms and a Very big update in general:

So far I've completed 5000 Kms on the Michelin Road 5 and I feel the tyres have just worn in!. The cornering grip is excellent(See below) and the tyres are a million times better than the stock MRF's.

Trip to Goa!:
Over a long weekend, I had made up a spontaneous plan with a friend who owns an RR310. The long weekend started from Thursday and the plan to ride to Goa or Kanyakumari was decided on Wednesday evening. We tried for a last minute booking in Pondicherry but could not find any rooms in our budget, so dropped the Kanyakumari plan and decided to ride to Goa!.

It took us 12 Hours including breaks to reach South Goa from Hyderabad. We were able to contact our AirBnb host from our previous stay in Goa a few months back and I was able to get a room at his place for 700Rs/Night (Excellent negotiations skills combined with us being repeat customers). We had a rough budget of 10,000 Rs/Person including fuel and expenses and we were able to complete the entire trip at 8000Rs/Person for 4 days 3 Nights.

The bike gave a full tank range of around 400 Km's including the ghat section. The bike performed amazingly on the ghats. I was scraping footpegs left and right and it even rained in while we were doing the ghat section. A Jawa 42 rider who was from TN was tailing us and unfortunately crashed due to the off-road tyres on his bike and the attempted aggressive cornering while raining.

We were able to maintain an average speed of 70Km/h on the ghat section and my friend who had come with me was amazed aswell. I feel I would not have enjoyed the ghats on the stock MRF tyres. I feel Michelin Road 5 make the bike way better than the stock tyres. These tyres also break really effectively in the rains as well as on the road. We were maintaining decent speeds even while it was raining.

We stopped to capture few pics before it started raining.

Now coming on to the bad part!:

I had gotten my oil changed right before going to the trip. I suspected that as Motul 300V is a racing type oil it may have been the cause for oil burn/ oil disapperance, hence got the oil changed to Suzuki Ecstar 9000 before the trip. I feel this oil is similar to Motul's 7100 line of oils and was smooth as well.

After coming back from the trip, I noticed that the oil was not visible in the oil gauge. I took it to the ASS and had the oil drained. 900ML was the oil which came out. took it up with the GM and the Suzuki big bike mechanic present there. Compression testing was done and they concluded that the entire cylinder has to be changed due to manufacturing defect in the engine. They put the bike back together, topped up oil to 1200 ml and asked me to ride the bike for another 500 kms after topup to see if the issue can be replicated.

After riding for 500 Kms, the oil level was not visible again and the drained oil was around 1000ml. the ASS spoke to technical team at Suzuki and got the approval for the entire cylinder and whatever that requires to be changed. So, the bike is again at a ASS waiting for parts and the ASS assures me that the bike will be completed in 1 week's time maximum (including sourcing of parts). I decided to leave the bike instead of getting it home as I hardly find time to ride the bike often due to the heat in Hyderabad.

I've attached few pictures of my road trip to Goa and also when I had to ride for 500 Kms, I decided to go to a place known as Srisailam near Hyderabad(220 Kms one way), Attaching them as well

To conclude:

The bike so far has done around 16,000 Kms and the downtime on the bike in 14 months of my ownership was almost 4 months. (2 months due to lockdown, 1 month due to parts not being available in Hyderabad, and the minor accident I faced). I feel the aftersales in a Hyderabad is a big miss for the last 12 months. I recently found a good ASS which is owned by Varun Group and they had a really competent technician and stocked almost all parts for the SF250, which is an achievement in itself. The GM has become a good acquaintance and the technician has over 15 years of experience working on big brands like Ducati and Triumph. Overall, the bike was reliable and never left me stranded anywhere.

I had this same experience on my CBR 150
after cleaning the throttle body completely, revs came down to 1.5k rpm
so i also support that this was not Battery issue,
it must have been IACV valve getting stuck

I had this same experience on my CBR 150
after cleaning the throttle body completely, revs came down to 1.5k rpm
so i also support that this was not Battery issue,
it must have been IACV valve getting stuck

Just a note on Speedo error.
Had on Google maps navigation and the speedo was showing 66kmph, while the Google maps is showing 60 kmph. I assume google maps is calculating speed using GPS which should be accurate. This gives a speedo error of 6kmph and I observed the same error in the range of 60 to 75 kmph speedo data. Is this a normal speedo error?

Yes it is normal. The speedo shows 10% more speed.
I think they do this for safety