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**rreneav1987** · 03-15-2013, 08:58 PM

Originally posted by rockyec78 View Post

Hey guys, positive update on the fuel pump issue.

I went to asc with all the suggestions as provided by you guys. But all my requests with Sr, Supervisor and service incharge were in vain, they were all insistent on paid replacement of fuel pump instead of providing the same under warranty. They also told me that they have contacted HMC people and they also have the same opinion. (The HMC Pune rgion office is located in same building where this SVC is.) They also said that if i have any doubt, then i can go an ask the HMC service incharge, but it wont be of any help. But the moment they felt i might go, he said that the HMC incharge is not in office and he will be available tomorrow only.
s)
He told me that i have to pay 11.5k for replacement. I told him that i cannot spare this much amount of money at this time, so please pack my bike and give it to me. ( i wanted to take it to different ASC but didnt told them same). They said it will take time to pack bike , come in evening (after 5 hrs), but i insisted that pack it up early, i will wait. They took another 2 hrs to pack my bike.
Meantime i went to HMC office contacted their service incharge, who also look after warranty claims. He was very positive. He went though my service book also, But didnt tell me once that i cannot avail warranty since i havent availed all free services. Then he contacted the Sr Supervisor from SVC i had my bike given to. The moment he talked with him, he
got biased and started saying same that i havent availed free services, blah ... blah.... but one thing was there that he was also not very confident of what he was saying to reject my claim. So i kept putting my effort in convincing him............ and man.....it worked. He started dialing to few people to know if they have fuel pump in stock, finally he got positive reply from another ASC. He told me although i am not eligible for warranty but still for goodwill they will change it as in warranty. I thought..... whatever....... i am getting it replaced without spending too much and thats what i was looking for so its ok, He said that only thing is that i have to somehow take may bike out of the the current SVC and take it to the ASC he has contacted. I agreed to that and, now i will be taking it this new ASC.

I hope changing the fuel pump will finally end the problem i was facing.

Thats a good news.. but also get them to check the ignition coil wire.. just to make sure that it is not the culprit.. cos the ASC guys were ready to get the Fuel Pump changed for me in warranty.. but I told them strictly to check the wiring before changing the fuel pump and it fixed the problem..

here in your case.. if the ignition coil wire is loose.. you might be getting a new pump as well as solving the issue

don't worry.. everything will go fine.. it depends on the way you speak with them.. buttering them always worked for me

Originally posted by blizarder View Post

yes you are right. I didn't thought about that. Anyways putting a little petrol isn't gonna harm I suppose.

haha.. thats a good one..

very true.. little amount of fuel is not gonna harm it

but its gonna evaporate in 2 months of time

not much.. but it will slowly

**abhi7013** · 03-16-2013, 08:57 AM

Guys have a serious problem. Few days back, gear shifting was pretty hard. Upshifts were kinda smooth only at higher rpm. But below 5k rpm upshifting was impossible. As for downshifts I practivally have to stand on the lever! Clutch plate was replaced three months back. So I suspect gearbox. Wat would be the repair or replacement costs? And do you guys think its gearbox? And in first gear if I hold clutch and move wen engine is off, I get a sound like krrrrr

**Divya Sharan** · 03-16-2013, 09:30 AM

Originally posted by abhi7013 View Post

Guys have a serious problem. Few days back, gear shifting was pretty hard. Upshifts were kinda smooth only at higher rpm. But below 5k rpm upshifting was impossible. As for downshifts I practivally have to stand on the lever! Clutch plate was replaced three months back. So I suspect gearbox. Wat would be the repair or replacement costs? And do you guys think its gearbox? And in first gear if I hold clutch and move wen engine is off, I get a sound like krrrrr

Cam tensioner? Not sure. Can you call Gowtham (MaxZma) and ask him? Pmed you his number.

**Touseef Ahmed Mohammed** · 03-16-2013, 09:38 AM

Originally posted by abhi7013 View Post

Guys have a serious problem. Few days back, gear shifting was pretty hard. Upshifts were kinda smooth only at higher rpm. But below 5k rpm upshifting was impossible. As for downshifts I practivally have to stand on the lever! Clutch plate was replaced three months back. So I suspect gearbox. Wat would be the repair or replacement costs? And do you guys think its gearbox? And in first gear if I hold clutch and move wen engine is off, I get a sound like krrrrr

Might be a serious problem with Gearshaft.
Or even gears messed up.
One of my friend got his Zmr done with gears & some minor problems.
The bill was around Rs.5,700/-

**abhi7013** · 03-16-2013, 09:48 AM

Discovered the source of issue. I guess. The clutch cable is loose. So every time I downshift while slowing down, holding the clutch, the rpm raises a bit as if clutch has no effect. But while idling in any gear, the bike is in the verge of switching off. So might be the cable thats making the gear shifts hard?

**ashwinprakas** · 03-16-2013, 09:53 AM

Its the clutch, its not disengaging properly, you're able to upshift because when upshifting you dont actually need to use clutch to rev match, but when downshifting you need to use clutch to match revs cause the revs of the primary and drive would be completely off, and to shift without using clutch you need to really slow down and open and close throttle while downshifting.

**abhi7013** · 03-16-2013, 10:09 AM

Originally posted by ashwinprakas View Post

Its the clutch, its not disengaging properly, you're able to upshift because when upshifting you dont actually need to use clutch to rev match, but when downshifting you need to use clutch to match revs cause the revs of the primary and drive would be completely off, and to shift without using clutch you need to really slow down and open and close throttle while downshifting.

And since I forcefully downshift, I guess its da reason why am getting that krrr sound

**Divya Sharan** · 03-16-2013, 10:12 AM

Originally posted by abhi7013 View Post

And since I forcefully downshift, I guess its da reason why am getting that krrr sound

Darn, I take back my words. Yes I completely missed the clutch free-play.

**ashwinprakas** · 03-16-2013, 10:22 AM

Originally posted by abhi7013 View Post

And since I forcefully downshift, I guess its da reason why am getting that krrr sound

And since you forcefully downshifted you "TECHNICALLY" might have hurt the tranny, most probably bent a shifter fork or something, but personally, During a few off roading escapades I've been in some real tight situations where I've had to kick the shifter hard to downshift while at WOT, and yet no issues from the tranny side, though the spindle teeth is worn out and gives double feedback most of the time, which I've learnt to live with, so next time check the shifter spindle teeth, and replace it if needed, and IIRC the Splendors can be used in the ZMA, and Vineeth bro had also mentioned that he's using it and its of better quality than stock one.

**sarbanoxley** · 03-16-2013, 10:23 AM

Self-delete.

**pixantz** · 03-16-2013, 02:49 PM

Originally posted by Shreeni0403 View Post

I don't agree here. The fuel is supplied to the pump via fuel filter through the pipes, nothing is submerged in the tank !!

What makes you think that the fuel pump is not submerged and fed fuel through pipes??? Just wondering.....

Sent from my iPhone using xBhp Connect

**Above_All** · 03-16-2013, 04:10 PM

Since dust & injector cleaning is discussed in last few pages , i would like to say , Translate dust to Hindi or Marathi , i.e. my City name Don't know why it is but we have to deal with lots of dust here . Never have any issue with injector , not using any cleaner . Just once RPM fluctuation happened .

Originally posted by psr View Post

Spoke to the HH chief tech on the Fuel Pump problems...he says the fuel pump being a DC motor has Carbon brushes , just like in the Self starter, which wear over time...this is a replaceable component, and a good mech will be able to do it, and the pump will be back to normal.....He also said that Air Lock in petrol line is another problem which had been corrected now by HH...owners can try with their SVC on both the points....
Hope this info is useful to ZMR owners....

Sir what is mean by air lock ? Is it something like in some old cars/jeep catch air in fuel line when running on low fuel & it need to be removed . Never heard of such problem in any ZMR yet .

Originally posted by sarbanoxley View Post

Self-delete.

What was that ?

Originally posted by pixantz View Post

What makes you think that the fuel pump is not submerged and fed fuel through pipes??? Just wondering.....

Sent from my iPhone using xBhp Connect

Cause it is located below tank . Completely outside of tank . Just check any ZMR at a point where normally fuel knob is located in other bikes , you will see a cylindrical black box . That is Fuel Pump .

**ashwinprakas** · 03-16-2013, 04:22 PM

Originally posted by Above_All View Post

what is mean by air lock ?

Air cannot be pumped due to its high compressablility, so it stays in the line and wont allow fuel to pass.

**Above_All** · 03-16-2013, 04:50 PM

Originally posted by ashwinprakas View Post

Air cannot be pumped due to its high compressablility, so it stays in the line and wont allow fuel to pass.

Ok so it is like the same situation like found in most of carb bikes running on low or out of fuel & then refused to start after filling fuel .
Not heard of such a thing in ZMR .
PSR sir if you find any info on what was changed please share it . Nothing different is found in 2009 & 2012 models spare manual regarding fuel setup .

**abhi7013** · 03-16-2013, 07:29 PM

Guys, managed to go til college. But later while inspectin the problem, the clutch cable got cut. I guess the cable was pretty loose and was holding by a strand or two. So had to tow bike. But later managed to switch on bike while moving slowly and change the gear to second. The bike would obviously jump and switch off when I had to stop in traffic. My enquiry is, would the gear box be harmed and to what extent. As ashwin said, upshifts were no problem but downshifts I had to do when rpm was extremely low. What would happen to my gearbox? The mech said once in a while if we do so, it won't harm. Btw, ithe distance I travelled without clutch is 20kms, most of which is highway

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