Iam new to Xbhp. I own a 06 ZMA which is getting overheated after a short ride in city or after a 25km ride in highway. I ususally ride at 60-80kmph and changes gears at 4000-4500rpm. The bike has done 36000Kms. I checked the bike with HH Service Guys and they did an engine decarb, changed clutchplates, sparkplug, airfilter but the problem is still present. The engine gives burning smell and the tank heats up after a stop after a 20km ride, no white smoke is produced. The servive guys said the engine is perfect but the heating is there they checked the oil pumps and finds no problem. The heating is less after service although the engine oil is not changed and after a 400km it starts over heating. I took it to a local mech he too didnt find any cause and told that the engineoil is good and there is no need to change for another 400km the engine was ok for short rides and again it started overheating. I was using HH oil then and changed to AGIP racing4t Fully synthetic But there is the same problem although 400km intervel changed to a 600km. Every thing in the bike is stock other than the rear tyre which is 120/80 zapper. Nobody was able to find the problem.
Guys please help me.
Thanks in advance.

Iam new to Xbhp. I own a 06 ZMA which is getting overheated after a short ride in city or after a 25km ride in highway. I ususally ride at 60-80kmph and changes gears at 4000-4500rpm. The bike has done 36000Kms. I checked the bike with HH Service Guys and they did an engine decarb, changed clutchplates, sparkplug, airfilter but the problem is still present. The engine gives burning smell and the tank heats up after a stop after a 20km ride, no white smoke is produced. The servive guys said the engine is perfect but the heating is there they checked the oil pumps and finds no problem. The heating is less after service although the engine oil is not changed and after a 400km it starts over heating. I took it to a local mech he too didnt find any cause and told that the engineoil is good and there is no need to change for another 400km the engine was ok for short rides and again it started overheating. I was using HH oil then and changed to AGIP racing4t Fully synthetic But there is the same problem although 400km intervel changed to a 600km. Every thing in the bike is stock other than the rear tyre which is 120/80 zapper. Nobody was able to find the problem.
Guys please help me.
Thanks in advance.

Hey Dude,

Lemme know the shop address, need the Os-NB + Bosch-relay set for my ZMA. Thanks.

Cool bro, Do post a pic of before and after fixing the NB. want an illimination pic.

i will probably get it in a month or two!

bro satish, do u have any idea about the bosch relay for zma r...i wud like to try it on my bike.......

No idea bro, dont even know where to find it. There is a Bosch dealer at ranigunj, but i think he is dealing only with tools!

Karizma wont need coil rewinding because unlike in a Pulsar the ZMA has a 188W Alternator on which you can put a 100/90 directly. Just make sure you have the correct relay installed.

whoah!! I didn't know the ZMA had such huge wattge on its alternator. No wonder then that with a relay in place my bike is running just fine with a 100/90 bulb plus a tad brighter pilots. been three months now and no issues whatsoever.

bro plz help in selecting a good relay for my ZMA R.....i ahve installed a new osram night breaker with 55/60W...

bro any car headlight relay will do the job for you, go for whole relay kit( as shop keepers call them) which include relay, wiring and holder, this will make the work easier. I was using Bosh relay before with NB but now i have a minda one both are good and even you can go for Aspa brand, all these relay units are used by cars in majority so you may not find them in bike accessory shops. These things are available in every auto electrical shops, atleast in Bangalore. All the best.

thanks bro vineeth...i have no clue anything abt relays...ill chk with car accessories shops here in hyd....if i find one, i will get it bro will the electrical mechanic people knw how to install them.....also please let me know the price... thanks dude!!

Any time bro, yes an auto electrician can do the job, if you are interested in DIY then even you can do it, its not a rocket science. When i bought my relay, i got it as a unit\kit as mentioned in earlier post and coast me around 400 bucks including labour charges but this was before 2 years and i've no idea about the new rates, if any.A relay alone will coast you around 120 bucks.

bro first lemmie know the milage of ur bike and does bike give some sought of missing while blasting above 120km/h....and if milage stands above average then it could be lean mixture try and check jet and if require change it as this is main cause of engine overheating due to loadelse final verdict is timing chain if its even a little tight it will screw ur engine internally and the first stage is overgeating...and remember faulty timing chain does not make sound everytime ..good luck

Engine decarb at 36k? Is that required guys?

And after all this, all I can think of is a lean AF mixture. I am sure you'd have thought of it. But I can't think of anything else !!

could be due to very lean AF ratio.


PS - where is oil pump located in karizma?

Already checked with the AF ratio its somewhat perfect.
They told that oilpump is near the clutch. I think its the pump which pumps oil to the clutch for cooling.

My Bro was using this bike and he told the heating and smell was ever since the bike was bought and he didn't cared about it.
And I can't believe with this type of heating it reached 36k.