thank you pinakiji. I have never changed chain or sprockets.

@int86
Welcome to xbhp,
Do you feel jerk when u leave the clutch? Or while u keep pressing the clutch??
I'd first suggest u to check your clutch lever, i think it has too much free play. The free play should be 10~20 mm in the end of the lever.
Check that and report back.

I checked the fuel mileage again after a long gap . The engine oil is 10w30 Gulf synth 4T and the tuning is set a bit lean as per Sibun's advice on my last plug chop . Reserve to reserve, it is consistently giving 71kmpl (like it's stuck there ) time and time again of testing . This is when I fill 2 liter and finish it up in 2-3 days , 50% congested city riding below 40kmph and rest is between 40-60kmph straight runs . However often now, it takes more than a week for me to finish that 2 liters (since I am constrained to take public transport many days now) , and then I get 58-60kmpl only . I am careful to turn the fuel cock off whenever I park my bike but it's blazing sun outside already now .... Is that much fuel lost from the tank by evaporation only ?

I too get similar mileage when I keep my splendor in my home for a week(or more than 3 days). I think petrol deteriorates as it is parked under shade.

I find petrol vapors condensed on the filler cap of my Xtreme whenever I open it. Petrol evaporates while riding in sun and condenses during nighttime.
(Because it has a one way valve and vapors are not allowed to escape into the atmosphere.)

A full tank in splendor will last me at-least 1 month(600 kms) easily !

OT-
1.Suddenly this thread has become dull.

2. @Pinaki -Did you get Paul's PM ?

Yes I think I got paul's message a coupla weeks back about catalogue .
I don't fill more than 2-3 lits at a time nowadays because of low usage and I don't want the petrol to go stale . Don't keep petrol for more than 2 weeks .
That is because I am not finding enough time en-block to tinker with the bike and post silly things here , maybe you all should take that up for me for now . Moreover Sibun is away and busy I guess ....

memorable experiences

This has not become dull, but has gone into hibernation, but again will start to pick up may be all are busy. I am busy particularly as march has just gone and you know in Banks march has hell lot of work.
As you know i have changed the clutch bell, GPT and clutch plates of my joy, but the crank is playing spoilsport and is marring the riding pleasure. May be next month, i will open the complete engine.
On another note as shoeb has bought an extreme, so shoeb can know how difficult it is to share time between two threads to update both threads.

We can start by sharing some memorable events with our bike which made our bike so dear to us to continue this thread before again any technical topic comes up.

Ok, here goes my one of the memorable experiences:-

It was in third year of engineering, that a crazy idea came to all of our friends mind, that in the dusherra holidays we all will go on a bike trip to Raipur and bhilai, a distance of 558 km. I had done several long trips on bikes, but this was quite long. As you know in engineering most of the guy had bigger bikes. We were 6 friends, 4 of my friends had P150, Unicorn, Karizma and a P200. I had only JOY. Other friend had a maruti swift which he will bring as for carrying luggage or we can say back-up car. All those were quite rich guys. As with guys now they all had their girl friends and when theygot the news they insisted on going on the trip. Now it was a tension to them as i do not have girlfriend, so i do not had to worry about it , at last they decided to take thier GF but all the girls will go in the swift with the sixth friend.

So plan was set up for leaving bhubaneswar, by six in evening when the first holiday begins. Now my friend asked me to go by being a pillion with one of them as i had joy and they had bigger bikes. But i insisted, that either i will take my joy or i will not go on the trip. They knew how much i loved my bike, so they agreed.

So as planned we got out by 6 in evening and since it was evening that too the begining day of PUJA holidays, traffic was quite heavy, and we passed cuttack after almost 1.5 hours. But from MANGULI square the road cleared up, and we were easily cruising at 70-80 kph. I think my friends were knowingly going slow(70-80 is slow for them) and till know i feel they were really adjusting with me. But we were cruising with a formation 2-2-1 and the swift following us. The bright light from the swift running 90/80 halogins helped us in night.

But the thing that i clearly remember( too bad i couldn't take a photo, as i didn't had a mobile even in 3rd year of engineering) is that at Angul, we stopped at DHABA for dinner. It was around 10 in night. It was a typical DHABA with cots lying to rest. We had our dinner and the girls had it in the cars as you all know DHABAS are not safe in night. After dinner it was decided that we will rest for 0.5 hour here. The scene is like this:-

My JOY was parked by side of cot and i was sleeping on the cot looking at it with the light reflecting of it in the night. Man i cannot describe it in words and till now every night i dream of it.
Then we continued till the orissa border, where it was decided to fill petrol, i had almost half tank still left. But still all the bikes and the car was filled with petrol. I remeber the PETROL station was bharat petroleum and was the only thing there as there was not a single other house there, I was completely excited as on either side there was no one and it was 3 AM in night which gave it a kind of excitement.

All those excitment got thrown out of window when we entered chattisgarh border as the road was horrible. This continued till some 30 kms from raipur where road improved a lot,with highway being built, but there were a lot of diversion. This was in year 2009, may be the roads would have been completed by now.

The return journey after 3 days was also like how we went without any events. It was a round trip of 1500 km and my joy performed extremely well, even I didn't suffered a single puncture which was quite reliable.Also this trip increased the bond among we all friends and we are in contact everyday till now and hope to rermain so forever.

When Doubts have been correctly answered, Methods of DIY clearly explained , and understood , and you have Sane members ,who are not expecting their 100cc bikes to behave/become as 650 cc bikes,....the thread will slow down and will have less posts.......many threads, including the ZMA have become one...
But the thread itself becomes a GOLD MINE to Newbies and future owners/Members ..

What matters is not forgetting the first bike. Many of us upgrade to a bigger/better bike and forget that bike which taught us the skill of riding,has given company in good and bad times,allowed us to experiment with it and ...... etc.

This summer has taken a toll on all my activities. I am finding it very difficult to go anywhere outside(due to severe heat) ,unable to stay comfortable inside(home) thanks to severe power crisis and power cuts in AP.

Ok,Let me start-off the technical discussion/interactive session.

Every part has some story to say and it is up to you whether you listen and pay attention to it. This interactive session will not only help one to re-build and understand engines the correct way but get to know the exact reason behind the root cause. Anyone can overhaul the engine but reading the parts is a skill and comes only with experience. It is useless to replace the parts without knowing the cause.
Remember sibun's post where his mechanic told the bore was worn "oval" just by giving a glance and without any actual measurements ?

Engine Parts Analysis PART 1- THE HEAD.



Carefully observe the head,notice the carbon deposits,its color, color of the intake and exhaust valves,wetness towards the lower side etc.
We will have an interesting interacting session so that we can all learn how to read the parts.

Now tell what you think about this engine,what state of tune it was running,what could be the condition of piston and bore,what could be the symptoms of the problems(if any).

Please Feel free to comment and DO NOT HESITATE. It does not matter who is wrong or right just let the comments flow !

hmmm on the outer edge of the cylinder head the yellowish marks are they burnt and glazed oil deposits?

any any engine will build carbon over time...even if the mixture is perfect(please correct if wrong)

the left valve is intake valve which bring in air and fuel mixture and lower temp and hence looks nice but the exhaust valve has to remove hot gasses out and a much more highter temperature envirnonment and hence the burnt carbon deposits on it

the piston head might have thick carbon deposit layer....no idea about any other things like piston skirt wear or rings and stuff

Good going. One small correction though - The valve on the left is actually the exhaust valve and the one with carbon deposits is the intake valve.

wow really...i never heard of intake valve with deposits and exhaust valve clean....how did that happen?
i also awlays though exhaust valves are bigger than intake valves and the one on the right seems bigger

so everything else apart from valves is correct?

Good initiative.....

1. The head Gasket is bust and head leaks oil..
2. The Rings are gone and/ or stem seal oil leak.....the plug will show black deposit just like in the head..
3. AFR seems ok...no burnt exhaust valve, and minimal inlet deposit....
4. The Engine head had been already worked on before....

To give some more clarity,I am posting this image.



Note the carbon deposits ,wetness only towards the lower side,leakage of Air fuel mixture past the head gasket and the resultant deposits,its spreading till the head's main oil supply gallery's o-ring (lower left studd)...........

Good going everyone !

a request psr sir...if possible can u give reasons as to how u reachd to the above 4 conclusions? so we newbies can learn

According to what i've experienced and learned so far...
The yellow marks clearly shows oil consuming. The carbon on that area is also thick and shining.
The oil consuming must be very less and smoke should be only visible at high rpm and that not too dramatic.
The oil may be coming because of leak from head small o-ring or if not, the ring gap would be more or wrongly placed but cylinder should be fine (i predicted this and may not be correct)
But i can surely say its valve oil seals are perfect. because the oil more come from intake rather than outlet. Oil easily can travel on slope from intake. but its cannot, from intake because of its slightly up direction.
The mixture was running correct. Moreover, two marks on its mating surface shows the head is already opened before and bike is re-bored once.

This is your pic and u know the truth. So let me know that!

@Shoeb
I have check that your new post pic later, so far what i've written above is only based on your main previous post. and have not edited/added anything later.

Now, the mating surface on both doesn't show any signs of used of gasket sealant or resibond. All mechanics and we used sealant, only factory made engines came with dry head gasket. Sooo, i guess, may be this had opened for the first time.