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Re: Karizma/Karizma R
In the recent month, I had got many issues with my bike, which enabled me to learn a lot (of course, the bike never stalled me anywhere and I was able to ride all the time). It was frustrating and consumed a lot of time. I had to be patient and try repeatedly and roam to many places to acquire things/tools and get knowledge from experts. Had to spend on net googling and gathering info. Made numerous calls to psr sir and spoke for hours and hours who patiently answered my unending queries; without whom I wouldn't have dared to do anything.
Coming to the issues I got:
1. Console flashing due to corroded terminals on top of relay. It gave me nightmares and it took me a lot of testing to identify the problem and rectify it. I described the whole issue before on this thread. I was able to learn a lot about the wiring of ZMA and now I am confident that I can solve any electrical issue in my bike. Before this, I didn't even know how to use a multimeter. I was able to strip the bike myself without going to any mechanic after this.
2. A combination of unstable idle, mental tapping noise when the engine is hot, low rpm knocking, lack of solid punch. I had same issues before I did an overhaul 10k kms back with a rebore to second OS (0.5mm).
To understand the problems, I had to go through so much of ordeal with lots of research and practicals. To rule out intake air leak, I replaced the carb insulator, AFR screw and the air injection tubes. The problem remained same. Checked the resistance values of TPS and found them to be faulty. Later when the output signal was checked, it showed correct voltage and it was all a puzzle. I thought of sending the the TPS unit to psr sir for clean up, but I was able to correct it myself in the end. This enabled me to learn what is a TPS and how it works.
Still the problem is same. Now comes the cylinder compression testing. Had been roaming around since months to find out a service center who can do the testing. Got fed up and bought a compression tester myself, but couldn't source the plug adopter for Karizma. Got to read a lot to know what size adopters were there for cars and bikes. Roamed for three days to get a plug adopter that fits in ZMA. Finally gave up and made a juggad with old spark plug and made an adopter myself. To get a simple nut with BSP threading, it took me a day. Finally I was able to check the compression and it showed 11 kg/cm2, normal being 13kg/cm2. To rule out gauge error, checked another Karizma and it too showed 10.5 kg/cm2. Puzzled again. Yet to get hold of a relatively new karizma and check the compression to rule out gauge error. Of course, the test confirmed that my bike doesn't have a valve leak, indicating proper valve sealing.
Now, its the turn of jets in the carb. The low end lack of punch might be possible due to clogged pilot jet. Had to read a lot of about carb to know how it works. With courage opened the carb myself and cleaned the jets. All was fine.
Still, the issues remain. Recorded the engine noise and showed it to psr sir, who suspected cam chain noise. Opened up the cam tensioner and checked its turns. Having an old working cam tensioner helped me in understanding how it works and was able to deduce that the tensioner extension was almost full, indicating increased chain slackness and/or cam chain guide wear out.
So, now the things that needs to be done are, cam chain and cam sprocket replacement along with guides, and also new bore kit at one go. Hopefully, the issue would be resolved then.
Checking the electrical issue.
The condition of TPS unit before cleaning.
TPS after cleaning.
Checking cylinder compression.
The reading that shows less compression.
Cleaning the carburetor and the jets.
Tools acquired in the process: Multimeter, Compression gauge, Force 46 piece tool set.
So, thats for now. Studying the relay setup for headlight done by my friend. Will post about it once I completely understand it.
NOTE: All the above work done by myself. I can be a little proud for that.
And thank you all who helped me in doing so, especially psr sir.
BTW, my bike completed 7 years a week back, with 75k kms on the odo.
In the recent month, I had got many issues with my bike, which enabled me to learn a lot (of course, the bike never stalled me anywhere and I was able to ride all the time). It was frustrating and consumed a lot of time. I had to be patient and try repeatedly and roam to many places to acquire things/tools and get knowledge from experts. Had to spend on net googling and gathering info. Made numerous calls to psr sir and spoke for hours and hours who patiently answered my unending queries; without whom I wouldn't have dared to do anything.
Coming to the issues I got:
1. Console flashing due to corroded terminals on top of relay. It gave me nightmares and it took me a lot of testing to identify the problem and rectify it. I described the whole issue before on this thread. I was able to learn a lot about the wiring of ZMA and now I am confident that I can solve any electrical issue in my bike. Before this, I didn't even know how to use a multimeter. I was able to strip the bike myself without going to any mechanic after this.
2. A combination of unstable idle, mental tapping noise when the engine is hot, low rpm knocking, lack of solid punch. I had same issues before I did an overhaul 10k kms back with a rebore to second OS (0.5mm).
To understand the problems, I had to go through so much of ordeal with lots of research and practicals. To rule out intake air leak, I replaced the carb insulator, AFR screw and the air injection tubes. The problem remained same. Checked the resistance values of TPS and found them to be faulty. Later when the output signal was checked, it showed correct voltage and it was all a puzzle. I thought of sending the the TPS unit to psr sir for clean up, but I was able to correct it myself in the end. This enabled me to learn what is a TPS and how it works.
Still the problem is same. Now comes the cylinder compression testing. Had been roaming around since months to find out a service center who can do the testing. Got fed up and bought a compression tester myself, but couldn't source the plug adopter for Karizma. Got to read a lot to know what size adopters were there for cars and bikes. Roamed for three days to get a plug adopter that fits in ZMA. Finally gave up and made a juggad with old spark plug and made an adopter myself. To get a simple nut with BSP threading, it took me a day. Finally I was able to check the compression and it showed 11 kg/cm2, normal being 13kg/cm2. To rule out gauge error, checked another Karizma and it too showed 10.5 kg/cm2. Puzzled again. Yet to get hold of a relatively new karizma and check the compression to rule out gauge error. Of course, the test confirmed that my bike doesn't have a valve leak, indicating proper valve sealing.
Now, its the turn of jets in the carb. The low end lack of punch might be possible due to clogged pilot jet. Had to read a lot of about carb to know how it works. With courage opened the carb myself and cleaned the jets. All was fine.
Still, the issues remain. Recorded the engine noise and showed it to psr sir, who suspected cam chain noise. Opened up the cam tensioner and checked its turns. Having an old working cam tensioner helped me in understanding how it works and was able to deduce that the tensioner extension was almost full, indicating increased chain slackness and/or cam chain guide wear out.
So, now the things that needs to be done are, cam chain and cam sprocket replacement along with guides, and also new bore kit at one go. Hopefully, the issue would be resolved then.
Checking the electrical issue.
The condition of TPS unit before cleaning.
TPS after cleaning.
Checking cylinder compression.
The reading that shows less compression.
Cleaning the carburetor and the jets.
Tools acquired in the process: Multimeter, Compression gauge, Force 46 piece tool set.
So, thats for now. Studying the relay setup for headlight done by my friend. Will post about it once I completely understand it.
NOTE: All the above work done by myself. I can be a little proud for that.
And thank you all who helped me in doing so, especially psr sir.
BTW, my bike completed 7 years a week back, with 75k kms on the odo.
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