Re: Karizma/Karizma R

The float chamber is like a reservoir for the fuel. The plastic mould in the reservoir is the the float and it works just like the round float in toilet tank. The float is connected to a valve. As the bike uses fuel from the bowl, the fuel level decreases and the float level also goes down and it in turn lowers the valve and allows fuel into the reservoir from the fuel tank. Once the fuel in the reservoir reaches the maximum level, the float also rises above, and the valve connected to it closes the inlet from the fuel tank.

Now, if the float valve is faulty in such a way that fuel enters into reservoir even after the maximum level, the reservoir gets more fuel and it will be drained through a drain pipe at the bottom. Check if you have the drain tube in place.

Fuel also leaks from the float chamber (fuel reservoir) if the gasket between the chamber and the main carb is faulty. You first identify from where the fuel is leaking. Check the joint between float chamber and the main carb.

You have to be more clear to identify the problem. Let us know from where the fuel is leaking and where its falling.

Re: Karizma/Karizma R

UPDATE: Today morning, I went to my mechanic and found a Karizma there, which is relatively new. The owner was not there so, I asked him that I will take out the carb and put in my bike for testing. I have removed the carbs from both the bikes and put the carb from other bike in mine and did a small test ride. I noticed significant improvement in knocking that I used to get. Acceleration was also crispier. Idling rpm was very good and stable, where as mine was fluctuating. As suspected by psr, Shoeb, and Sibun, my carb has some issue, more likely the throttle slide being sticky.

I have cleaned the carb thoroughly twice very recently. Everything was clean in the carb. Slide was going up and down and as I don't have any issue with achieving high speeds, I though it was working fine. Shoeb suspected a little stickiness in the slide ther other day. Today, as suggested, I was ready to clean the slide and the slide chamber with Scotchbrite, but after opening the diaphragm, I noticed that the slide is freely falling without any hesitation, and I didn't feel the necessity to clean it with Scotchbrite. So, I informed the same to psr. He suspected a slightly rigid spring and asked me to cut out three turns of the ring. I did the same and put everything back. The results were mixed. Immediately I noticed better response with less knocking and it seemed to idle better. There was no increase in acceleration, but the way it accelerates changed. The negative side is I am feeling more vibrations now when accelerate. After the engine is considerably hot, I still can feel the knocking and the idle also fluctuating.

Now, I am yet to do the other two mods suggested by psr above. Drilling a hole and putting a small watcher. It may take sometime for me to do those mods as I have to search for the items.

Coming to the exhaust smoke problem that has recurred again, I need to open the engine again and put new Dowel pins and a new gasket again. Hope to do that in the weekend as service centers are closed now due to festival season.

Also, I have asked my mechanic for any second-hand carb from anywhere, and also look for the possibility of swapping my carb with any other good ZMA from any auto consultancies. Lets see how it goes.

Re: Karizma/Karizma R

I am still waiting for Sibun's response. If possible, I will call him.
Here only Sibun and PSR have the experience.

Most probably my mechanic will be open tomorrow and it would be better to get the job done by him as he was the one who removed the engine, I am not sure and will let you know as it is Milad-un Nabi.

I am sorry that you are having to face the problem again.

Re: Karizma/Karizma R

My bike is asking me to learn more with practicals, so its posing me issues so that I can resolve them and learn. We will take it as a learning experience. The more you fail, the more knowledge you gain.

Maybe its difficult for me to come all the way to Malakpet again. If you are going to be there all the time, then I would come, else I prefer to open the engine near my place. Also, let me check the bike again tomorrow morning and see if it emits smoke again. Lets see how it goes.

Re: Karizma/Karizma R

Replies in bold.

Re: Karizma/Karizma R

@NIGHTMARE, Check the following picture. It explains the fuel overflow/leakage. If the fuel is leaking, it most probably means the gasket is defective. If the fuel is drained via the drain pipe, the float valve is defective.




@psr sir, please correct me if I am wrong.

Re: Karizma/Karizma R

Ravi Bhai you are totally correct. When you mention gasket it was confusion for me because I'm was aware of which part you are referring. Now with the help of your pic its very easy for patient (me) to explain problem and doc can provide me better diagnostic.

The fuel is leaking from drain pipe. Even in my case rubber piper is not present in that location and this reason I saw it otherwise I never noticed leakage problem. Three days ago my mechanic cleaned it. Afterwards no leakage and when I saw it next day I found fuel on ground. Total km I have done is 27000 and my bike is old almost 8yr.

Re: Karizma/Karizma R

Better get the rubber pipe for safety. The following pic shows the float and the valve. As the float goes up, the valve pin above goes into inlet hole there by closing it. There might be some problem with the structure. Ask the mechanic to check for any problem. The pic is not ZMA's, but its similar. I used this just for illustration.

Re: Karizma/Karizma R

Ya saw that in my cab its in white colour and I was there when he fitted float and valve. Ok I will asked my mechanic to reopen it and see whole thing again. One more thing to ask whenever the cab will be open the fuel & air mixture remain same because screw never touched or every time I have to setup ?


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Re: Karizma/Karizma R

It will be same. No need to adjust the AFR screw again.

Re: Karizma/Karizma R

UPDATE: Today morning, pulled the choke on and started the bike. For initial 10 seconds, there was no smoke from exhaust and it was puzzling to me. After 10 seconds, slight smoke started and it was there for 15 seconds and almost disappeared (visibly). So, the amount of smoke today was almost 50% less than previous day. The chronology is like, first morning no visible exhaust smoke, second day visible smoke, and third day visible smoke which is 50% lesser than 2nd day. Waiting for experts' analysis on this (@psr and [MENTION=28527]sibun[/MENTION] and other experts).

Afternoon, checked the compression of the combustion chamber, and it read ~9.5 kg/cm2, which is 1 bar lesser than the compression value I had with my previous bore. Obviously this says, there is a compression leak, either through piston rings, valves, or gasket.

Re: Karizma/Karizma R

Put a few drops of engine oil in the bore through the sparkplug hole and then check the compression.

Re: Karizma/Karizma R

I thought of doing that, but I got pissed off a bit after seeing the reading. Will do it now. Let me check where the oil can is.

Re: Karizma/Karizma R

[MENTION=43108]shoeb2015[/MENTION], just did it. Put a spoonful of oil in the combustion chamber. The compression increased 1 bar approximately than previous; it read 10.8 kg/cm2. Busted piston rings from a new bore is not expected from Hero. Had I done the work at Service station, I would have complained it to Hero with strong words. When has Hero become such standard less? Feeling really pissed off. Feel like using my old bore with new piston rings.

Re: Karizma/Karizma R

My mechanic friend says to check for scratches on the piston now as it might not have set in properly due to the rings.