"Where there is a will there is a way"

Below are the mentioned items i bought of second hand from bangalore's scrap yard aka 'gujri' in shivajinagar and some new ones

1. ZMR right clutch case(second hand)
2. pulsar 220 oil cooler(second hand) = 1500(inclusive of item 1 & 2)
3.o rings= 45
4. ZMR oil cooler pipes = 750
5. p220 oil cooler pipes=500
6. oil cooler hinges and oil cooler cutting and welding = 300
7. labour chrges= 1500




R&D and mods
1. Had both the left and right clutch case powder coated to silver color as ZMR clutch case is some what golden color. Make sure you have it washed properly before giving out to powder coating my mechanic gave the oil plunged case as it is and the etching process was not carried out properly now the coating is peeling off.
(suggest u keep it as it is wont make much difference)

2. Buy a zmr oil cooler and not p220 as it wont give u an exact fit and as in my case had to install horizontally like p220 and caused impact issues with fender so had to rise the front fork by 1inch (additional cost not mentioned).go for vertical arrangement by welding a clamp and mounting the oil cooler vertically giving you better cooling. I couldnt as i had already installed crash gaurd and fog lamps. Also it will save u amount on p220 oil cooler pipes


3. The zmr does not have kicker so had to cut the kicker shaft yet leave it engaged with gears as gears wont engage without this shaft and zmr clutch case does not have provision for its housing so here on ur bike will become kicker less.

So after all the trial and error my bike looked something like shown in the attached images.
[ATTACH]232189[/ATTACH][ATTACH]232190[/ATTACH][ATTACH]232191[/ATTACH]

PS. THIS PROJECT WAS DONE BY ME USING A SKILLED MECHANIC AT MY OWN RISK SO SHOULD ANYONE WHO WANTS TO DO THIS MODIFICATION ON HIS.

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Hi there co-XBHPIAN i have already replied on this thread with images. Regarding your 09 R model i suggest you to a step by step engine flush using a good quality engine flush, then use a semi synthetic oil preferably shell ax7 10w40 for a try and a proper vehicle tune up from a skilled mechanic to reduce engine heat problems, roughness and vibration of engine if any before thinking of going for the mod.

PS : I did this mod on my bike as i am a vivid motorcycle traveller and use my bike for long travells which involves the engine runnning at high rpm for a prolonged period.If you are travelling for short distances no need for this mod as karizma is detuned version of honda crf 230 and has proved its mettle internationally.

I own a ZMA R 2012 july model (about 1.7 lac kms on ODO).

[ATTACH=CONFIG]252147[/ATTACH]

I had an issue of engine oil drain, if I ride speeds above 90. So decided to get the bore changed and also few more things fixed.

Major Changes include

1. Bore kit
2. Gear wheels (2, 3, 4 and 5)
3. Complete body kit apart from fuel tank (Ordered from Safex)
4. Drum plate of rear wheel
5. front Disk and disk pads.

Other misc parts including cables, fuses, plug etc.

More details soon.

Brother how good is the body parts from safexbikes?

They don't fit properly be prepared for sanding.

But they are really cheap when compared with oe parts. If it is made of strong and good quality material, I think I'll try those when I need fiber parts for zma next time. Please do share your thoughts on the quality of the product.

Brother how good is the body parts from safexbikes?

Hi I have a karizma r 2007 model,the bike is doing well the only problem i have is the left switch assembly(indicator,horn, choke side) its broke and not working properly I want to replace them but cant find in local shops and online .
now my question is can I change it with any other model bikes switch? please help.

First gen CBZ Xtreme and old Honda Unicorn have the same switchgear. Check for the wiring. If they match, you can easily swap them.

is there any way to replace the lcd display in meter console...mine is damaged

They are sealed ones like in any other console. Either OE full console or ,Look out for aftermarket or at breaker's yard.
If you have meter console repair shops in your area, then they will be able to get you one from another console..