Re: Hero Honda Karizma ZMR

FYI, check the rusting of the silencer. was powder coated twice, last being 4 years back, still back to square one, functional performing absolutely fine. No complains either on the 1.25L kms run bike.

Re: Hero Honda Karizma ZMR

Hey Guys, Coming back to our ZMR thread after some time.. Hope all along with their ZMRs are doing great

BTW, a few updates from my end.. I have finally completed the run in period on my ZMR.. !! 2000 KMs completed without any show stopper.. happy n kinda relaxed as i can now plan to revv it up a bit more..

But had some issues at the same time too.. I had been continuously feeling those irritating vibrations at the foot pegs & handle bar.. The vibrations used to be quite prominent once i crossed 60-65 on speedo & that used to be such a spoilsport not that the engine erred in providing the pick up or stopped going beyond a limit.. i mean i though not so very happily but used to cruise at 90 kmph without any additional trouble.. However having said that I always felt as if the engine was never really so happy giving that output.. I could always feel that extra resonance & bit of extra noise (even while revving down without applying clutch after revving up for some hundred meters) .. as if it used to get angry if i revved !!!!

Got my second service done earlier than planned so that i can get that stupid vibration issue attended.. but to no avail.. Therefore brought the bike again to the SVC a week after the second service... Luckily i have one senior supervisor close to me at the SVC & i asked him to check the vibrations & noise personally.. He test rode along with one of his trusted senior mechanic & came back with a shocker "Bro, your bad luck; there is a major issue with the engine & we need to open it & replace some major parts;" !!! I was like "what !!! this is a 3 month old bike & you are gonna open up the engine !!" But somehow decided to let him do whatever he wanted & left the bike at SVC.. I just trusted him as he is close to me.. Finally got back my bike after 3 days & also got a list of the parts they have changed..

1. Crank Shaft Component
2. Cam Shaft Component
3. Arm Valve Rocker
4. Bearing, Ball Radial

All these things though came under warranty, but i still had to pay 900 bucks for consumables..

However the best part of the story is my engine has really become way smoother n relaxed than what it used to be !!! Vibration has been reduced to a significant extent & I feel way better while ridding it now.. Phewww.. Finally !! Though i refrained from revving it as these are major parts & they would again need a bit of run in.. But am sure the replacement of these parts has definitely helped.. Still fingers crossed; lets see how things turn up after 500 KM from here..

Re: Hero Honda Karizma ZMR

Initial ZMr 2009 models had some problem in the above mentioned parts...but the new ZMR has been improved a lot and i assume this is a first case i am hearing to have parts changed in a couple of months from purchase...

Re: Hero Honda Karizma ZMR

Guys, Please Ready Fully and Reply. My ZMR ki life ki sawal hein

Guys, I got my ZMR on 3-5-2013, yes, exactly 1 year back and has done 9000kms only. I did complete the run in period properly but, in between had a short shoot upto 100kmph, even though the acceleration was gradual without much sudden twist of the throttle. It used to give me around 45 kmpl in mixed conditions but after the 4th service, it dropped a bit, and now I am getting around 40kmpl.

My bike's oil gasket was somehow damaged before the 4th service and it ran on low oil and my bike used to be somewhat rough. I thought it may be because I had not changed the oil for a long time (I did the 3rd service in november 2012 and 4th in february 2012) and I did not use the bike for about a month coz of a small accident that caused my finger to break. I had to ride the bike around 150 kms from my place of work to my home and usually cruize at around 85 kmph coz the road is mostly highway. But in between there were some teens provoking to race with me in their R15v1.

Initially I did not mind them, but finally I took a shot, and realized I was taking time to get to the topspeed even though I won the race as there were some traffic on the road. After the race, the bike became much more rough, and I felt as if I am riding an old pulsar. I reached home somehow without engine stalling. As I was sure, there was some issues with the bike, I decided to check the engine oil level, and I found the oil level was "NIL" Of course some slight amount of oil was there, as I started the engine, turned it off and checked the oil level, the lead was showing some signs of oil on it I called the service center, and they asked me to go there. They advised me, it wont be an issue if I ride for 5 mins without oil (Service center is about 6 kms from my home). Reached there, they topped up the oil, found some serious oil leak, asked me to change the oil gasket, and charged me around 500 for changing it as it comes under consumables.

After this incident I used the bike for nearly 3500 kms, in mixed riding conditions, mostly over 85 kmph, but I should say, the vibrations were increased considerably and there is a slight decrease in mileage and pickup (mainly with pillion). There is no change in the exhaust note and all, the smoke coming out is colorless, but is having some odor. I am not sure whether all ZMRs will be having the odor, as I dint check it before.

So my questions are:

1. Has my bike's engine undergone any serious damage during the incident
(100 kms without/less oil, around 10 mins insane driving at topspeed of 125+, and most other times above 85)

2. What must have caused the decrease in mileage?

3. Service center changed some bushes and all, but still vibrations are there from 55 to 65 and more than 85, vibrations creep exponentially. I can literally hear my front cowl vibrating, and I cannot see anything on the RVM (I have ridden P220 several times, and the case is similar to stock P220 RVMs)

4. Can anyone describe the process of removing vibrations by adding double sided tape or rubber pieces with PICTORIAL ILLUSTRATIONS as me and my service center mechanic is literally clueless about where to apply these tapes and stuff. Many guys tell to apply the tapes where metal parts meet the plastic parts, but already rubber bushes are there in such places in the ZMR

Re: Hero Honda Karizma ZMR

1. Depends. If the oil drop was significant, then 100 kms is enough to damage the engine. You were lucky the engine didn't have a seizure.
2 FE loss maybe attributed to old spark plugs, dirty air filter, worn out chain sprockets.
3. Vibes and double sided tape - chuck double sided tapes, use rubber tubes. Ask your mech to put the tube around the speedo console and under every screw mount. Also get your front sprocket cleaned off muck. Do you lube the chain?

Re: Hero Honda Karizma ZMR

Originally posted by vishnurajanme View Post

So my questions are:

1. Has my bike's engine undergone any serious damage during the incident
(100 kms without/less oil, around 10 mins insane driving at topspeed of 125+, and most other times above 85)

==> 100 km without oil can surely cause a serious damage...but having less oil for those many km shouldn't be the reason behind your problem.. well then the question is "how less it was" !

Man, I used to ride my Kawashaki Caliber at it's top speed for more than 20 km at stretch in year 2000 & I never faced your current issue even then & with a low end bike! Therefore if riding over a mere 85kmph or at a top speed can cause such damage to a ZMR then I would definitely sell it off in the next one hour

I have one question though; I always got the impression from some of your posts that you are somewhere a revv friendly guy.. Then what prompted you to buy a ZMR ??

----consecutive posts auto-merged-----

Folks I too need an urgent help..

As i have mentioned above, i had my ZMR engine opened up & come components were changed to arrest the engine sluggishness/vibrations. However as i returned home I could hear a "thakkkk" or a "crrrrr crrrrr " sound when I pulled the bike in the first gear. I couldn't notice this sound at the SVC due to so much of noise around. But I can hear it clearly with some silence around. Now these kind of sound come only when the bike is stating to pull from a very low speed: mainly in the first gear. But it doesn't come once i move to higher gears & attend a bit of speed.

I took the bike back to the SVC thinking it might be due to chain tightness or sprocket misfitting. But all those things are fine. Infact SVC changed the rear sprocket bearing & We all felt as if the issue has been resolved. But the issue resurfaced as soon as i returned home

Can anyone of you please let me know from your experience as what might be the issue ? Have they not fitted the engine components correctly? Should i ask them to reopen the engine & check ? Have anyone of you experiences a similar issue when your engine was worked upon previously ?

I am taking the bike back to SVC tomorrow. Any suggestion from your end would help a gerat deal. Thanks in advance..

PSR sir, if you are listening, any idea ???

Re: Hero Honda Karizma ZMR

I am not sure. The service center guys must have done that coz I give the bike for free service at correct intervals

----consecutive posts auto-merged-----


Answers in bold

Re: Hero Honda Karizma ZMR

Well, when do you hear it and did you try to locate from where the sound comes from?? "when I pulled the bike in first gear" by this statement, did you pull it with the bike engine running and idle?? what exactly are you trying to do here? do you hear that sound only after the engine heats up?? try to identify from where the noise is coming from!

Re: Hero Honda Karizma ZMR

Switch over to xxW40 oil and get your tappets adjusted.

SVC folk use used oil to wet the chain. Its good for the first 50 kms at max. Your chain is running dry. Buy a lube.


Ok, so I have done 10k kms on PSD. No punctures yet. (touch wood)
Still has enough life left. Rode in heavy downpour yesterday. Grip levels were too good.

Re: Hero Honda Karizma ZMR

Thanks a lot Divya & Vishnu.. I would ask the SVC guys to check on the tappet noise/valve settings..

Re: Hero Honda Karizma ZMR

Also, if my engine had some damage due to less oil, what all must have happened? Chances of piston loosening? I think it can be corrected by a big bore, right guys?

Re: Hero Honda Karizma ZMR

At max, you may have to change the block. That's the worst case, but since your bike is running, I feel we can keep that aside for now.
AFAIK, pistons don't get loose (I may be wrong), they can get stuck however. Reboring would mean that you'd never be able to use stock pistons again. (in the same block)

You can get oversized pistons from USHA or from P200NS. You'd need supporting gudgeon pins for the connecting rod since the stock ones won't work. Finally, if the work is carried out well, you'd have ~235 cc to play with! Then, run in for 1000 kms.

Re: Hero Honda Karizma ZMR

Correct me if I am wrong.. if its an issue with the Tappet.. isn't the noise suppose to appear throughout and not only when you are nearing the idle speed? but get the tappet adjusted to see if that resolves the issue..

If you can get the sound recorded and maybe attach it here.. it might help us identify it..

Is it a squeaking noise?? is the noise coming from the left side or the right side of the engine..?


it can cause the seizure of your Engine.. You said your bike is emitting smoke, didn't you?? it could be that the bike is taking in too much oil.. do one thing.. take it a local mechanic.. and just get him to ride your bike.. he might be able to give you the cause.. just to check as those guys have better knowledge compared to our so called SVC Mechanics.. Once you come to know what the problem is.. you can get the SVC guys to check on it.. FE can reduce due to many reasons.. try to figure out what is the recent change you did to your bike.. My Black Pearl Gives me an awesome FE till date and she is running smoother everyday.. (touchwood)

My Question to you buddy is.. if the piston of P200NS is oversized.. how comes its a 200cc?? Just confused..

and i guess you are right.. the picstons don't get loose.. the block gets seized and gets scratched by the pistons without oil.. thats what I remember from my Pulsar 180 correct me if I wrong..

Re: Hero Honda Karizma ZMR

displacement = bore*bore*0.7854*stroke*number of cylinders

Karizma:-
Bore - 65.5 mm
Stroke - 66.2 mm

displacement = 65.5*65.5*0.7854*66.2*1 (mm*mm*mm) = 223065.02757 cubic mm = ~223.06502757 cubic cm. Hence 223 cc

Pulsar 200 NS:-
Bore - 72 mm
Stroke - 49 mm

displacement - 72*72*0.7854*49*1 (mm*mm*mm) = 199504.1664 cubic mm = 199.5051664 cubic cm. Hence ~200 cc.

Now, when I plonk P200NS piston, bore increases to 72mm from 66.2mm and corresponding stroke reduces to approx 57.7 mm or so. (PSR/ACS would better explain how)

Hence displacement = 72*72*0.7854*57.7*1 (mm*mm*mm) = 234926.33472 cubic mm = 234.92633472 cubic cm. Hence ~235 cc.

Hope I was clear.

Re: Hero Honda Karizma ZMR

Crystal clear.. but what ll be the power delivery?? Would that be affected in any way?? I never wanna take risk with the precious engine of zmr.. is this a safer bet than joels?? And it should be cheaper i guess