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**ashwinprakas** · 06-21-2011, 04:13 PM

Update on my ZMA-R

Bought ROOTS WindTone &
BOSCH Relay.

Went to service center with Aneesh.. A decent looking old chap advised that it'd be wiser to bring the bike tomorow due to excess bikes they've received for servicing...
And so we decided to fix the windtone after completing the service....

And about the double feedback issue... LOL...IM LAUGHING!!!!!!!!!
I was worried so much that i didnt sleep yesterday thinking that the svc's are going to open up my new baby.... But aneesh's bro just took my bike for a testdrive... came back... did some adjustments.... AND..... YIPEEEEE Reduced double feedback.. Now its like in Aneesh bro's ZMA (we'd have to HUG THE BIKE(as psr sir said) to know it :-) )...

**ashwinprakas** · 06-21-2011, 04:15 PM

Originally posted by Aneesh@4GHz View Post

Nothing to calculate,just measure the gap,thats all.

Always LOCK the nuts tight to avoid loosening ,and increase in free play....if you see the pic above both nuts are tight on the retaining flange..

That means... I'l have to hold the clutch lever as shown by psr sir, and then tighten the cutch cable till it stops??? right???

**Aneesh@4GHz** · 06-21-2011, 04:18 PM

Originally posted by ashwinprakas View Post

That means... I'l have to hold the clutch lever as shown by psr sir, and then tighten the cutch cable till it stops??? right???

no,after adjusting the clutch,there will be free play in the clutch lever,it should be 5mm or less gap.

**ashwinprakas** · 06-21-2011, 04:22 PM

Originally posted by Aneesh@4GHz View Post

no,after adjusting the clutch,there will be free play in the clutch lever,it should be 5mm or less gap.

MMM...Just as i suspected....

I'll call you in 5 mins

..

**Aneesh@4GHz** · 06-21-2011, 04:41 PM

Guys put 2-3 drops of oil in the marked parts,gear feels little more smooth than before.

Try it guys.

**harishsangwan** · 06-21-2011, 05:42 PM

Originally posted by Aneesh@4GHz View Post

this is mine before overhaul,is your oil leaks looks looks like this?

I cleaned some some oil that was over the starter motor, before I went out to ride and now I am kinda certain that the leak is from the nut that has been marked in the be low pic:

It could be from the cylinder gasket as well, but the oil leak from the marked nut is evident.

**Aneesh@4GHz** · 06-21-2011, 05:45 PM

Originally posted by harishsangwan View Post

I cleaned some some oil that was over the starter motor, before I went out to ride and now I am kinda certain that the leak is from the nut that has been marked in the be low pic:

It could be from the cylinder gasket as well, but the oil leak from the marked nut is evident.

It might be the Tensioner gasket.There is a gasket in between the tensioner.

**harishsangwan** · 06-21-2011, 05:45 PM

Originally posted by psr View Post

Your clutch set up needs adjustment...When you pull the clutch lever you should have only 2 to 3 MM of Free Play...More than this will not disengage clutch fully and you will be trying to shift at partial clutch...adjust play by tightening the nut of the clutch cable holder....on the engine case..

The issue I had about gear shifts during stand still not resolved, even after adjusting the clutch free play. Also, I noticed that gear from 1st to 2nd doesnt happen at one go. It ends up at neutral mostly. What else could be the reason?

**harishsangwan** · 06-21-2011, 05:50 PM

Originally posted by Aneesh@4GHz View Post

It might be the Tensioner gasket.There is a gasket in between the tensioner.

So its called 'tensioner'. Dint know that, even the Karizma Catalogue doesnt show the same.
Can I change the gasket myself by removing the starter motor assembly?

Originally posted by harishsangwan View Post

Before checking all this, I went for a short ride to warm up the engine and then was checking the oil level. Shockingly the oil level looked to be even lower than the 'lower' mark

not sure if I did something wrong there. But checked the same 2-3times but same indication. Did this with the bike on the main stand. Is this possible?

What you have to say about this?

**Aneesh@4GHz** · 06-21-2011, 05:58 PM

Originally posted by harishsangwan View Post

The issue I had about gear shifts during stand still not resolved, even after adjusting the clutch free play. Also, I noticed that gear from 1st to 2nd doesnt happen at one go. It ends up at neutral mostly. What else could be the reason?

When did you changed engine oil @ last?

Originally posted by harishsangwan View Post

So its called 'tensioner'. Dint know that, even the Karizma Catalogue doesnt show the same.

Here it is in the Catalouge.

Can I change the gasket myself by removing the starter motor assembly?

Yes,Its an easy task,Someone in the forum had replaced the tensioner itself.

Before checking all this, I went for a short ride to warm up the engine and then was checking the oil level. Shockingly the oil level looked to be even lower than the 'lower' marknot sure if I did something wrong there. But checked the same 2-3times but same indication. Did this with the bike on the main stand. Is this possible?

Oil may stick to the engine walls after a ride,so after a ride,put your bike in middle stand and keep it for 20mins and check again.

**harishsangwan** · 06-21-2011, 08:00 PM

Originally posted by Aneesh@4GHz View Post

When did you changed engine oil @ last?

Its been 1000kms since I changed the oil. But then had the issue before reaching the 1k kms.

Here it is in the Catalouge.

I knew I wasnt looking hard enough

Yes,Its an easy task,Someone in the forum had replaced the tensioner itself.

Will search the topic and see what I can get.

Oil may stick to the engine walls after a ride,so after a ride,put your bike in middle stand and keep it for 20mins and check again.

Shall check the same later.

Thanks for your replies. Have replied in bold.

**harishsangwan** · 06-21-2011, 09:53 PM

Originally posted by santoosh View Post

I changed the cam chain tensioner Myself yesterday ,
420 rs , No difference in Quality , Its the same and does the Job well..

Santa

Hey Sant, found this reply of yours after a lot of searching.

Could you help me change the tensioner gasket? Need to change it coz I suspect the oil leak from there and as suggested by Aneesh, the gasket might need a change.
I was planning to do it myself, but then the starter motor in an hinderance. Tips from you would help me get through this one.
EDIT: Forgot to ask. What does the tensioner do?

Also, I was planning to buy some spanners and wrenches to help work on my bike. I already have the toolkit that came with the bike but then its not good enough. What do you guys suggest?

**Aneesh@4GHz** · 06-21-2011, 10:43 PM

Originally posted by harishsangwan View Post

Its been 1000kms since I changed the oil. But then had the issue before reaching the 1k kms.

Are you using HH oil? If yes,the change it to any JASO MA2 Spec oils like Gulf,Shell,motul,etc and see the difference.

Originally posted by harishsangwan View Post

Forgot to ask. What does the tensioner do?

It adjust's the tension of calm chain,like it help the cam chain not to jump out of the teeth.

Correct me if i am wrong.

Also, I was planning to buy some spanners and wrenches to help work on my bike. I already have the toolkit that came with the bike but then its not good enough. What do you guys suggest?

Already answered by PSR.

Better to get Box spanner head of...8 , 10 , 12 , 14 , 17 , 18 , 20 , 22 , mm heads and one Ratchet handle for same(bi directional rotation )the heads will cost about 65 to 75 each and handle 150 to 350 depending on quality...buy combination spanners of same size with ring at one end and open spanner head at the other..and one each of star and flat blade screwdriver of medium duty.Totally will cost you about 1,500/-.

**santoosh** · 06-21-2011, 11:03 PM

Originally posted by harishsangwan View Post

Hey Sant, found this reply of yours after a lot of searching.

Could you help me change the tensioner gasket? Need to change it coz I suspect the oil leak from there and as suggested by Aneesh, the gasket might need a change.
I was planning to do it myself, but then the starter motor in an hinderance. Tips from you would help me get through this one.
EDIT: Forgot to ask. What does the tensioner do?

Also, I was planning to buy some spanners and wrenches to help work on my bike. I already have the toolkit that came with the bike but then its not good enough. What do you guys suggest?

Step 1 . On the RHS of the bike , U ll find the Grounding wire on the Self motor Bolt. Use a ring and Open that.
Step 2. Once u have removed the wire , the Trip meter and CLock gets reset :-) Congrats
Step 3: Another bolt on the Self motor , remove it.
Step 4: Come to the LHS of the bike , Take a screwdriver and a hammer and push the self motor Out..Little oil will come Out , Normal.
Step 5.Once self motor is out , U can see the tensioner easliy.
U ll need an impact screw driver to get the screw out .
Step 6. GEt it out ,Do whatever circus u want ..
Step 7:Step 6 to step 1 in reverse order.

Tensioner controls the slack on the cam chain , Tensioner is nothing but a pre loaded spring .

Hope i helped .

Santa

**psr** · 06-21-2011, 11:18 PM

Originally posted by santoosh View Post

Step 1 . On the RHS of the bike , U ll find the Grounding wire on the Self motor Bolt. Use a ring and Open that.
Step 2. Once u have removed the wire , the Trip meter and CLock gets reset :-) Congrats
Step 3: Another bolt on the Self motor , remove it.
Step 4: Come to the LHS of the bike ,
Remove the self motor gear cover by undoing the three bolts on the cover Take a screwdriver and a hammer and push the self motor Out..Little oil will come Out , Normal.
Step 5.Once self motor is out , U can see the tensioner easliy.
U ll need an impact screw driver to get the screw out .
Step 6. GEt it out ,Do whatever circus u want ..
Step 7:Step 6 to step 1 in reverse order.

Tensioner controls the slack on the cam chain , Tensioner is nothing but a pre loaded spring .

Hope i helped .

Santa

Santa ...I Just added another step..hope you approve

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