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**psr** · 10-05-2011, 07:36 PM

Originally posted by Aneesh@4GHz View Post

Thanks sir,Actually Sarin Bro done it,we had tried but failed and lost compression(Over Tighten ) after that sarin bro helped us,loosened it and showed us how to do it.But the T mark confused us a lot,its not working when its on the T-Mark.

When adjusted on the T-Mark,it sounded like a Sewing machine.

what you found as "T" mark may be for setting the Ignition timing,which only the factory people will know,because a TDC mark cannot shift ,since the rotor is locked in place on the Crank shaft with a wood ruff key.

**SriramEfunds** · 10-05-2011, 07:43 PM

Originally posted by Aneesh@4GHz View Post

Enquired today,everything is out of stock here,luckily we got 2 tappet O-Rings,only 2 of them were left,we bought it.

and finally after spending one day adjusting and had some errors we are doing this for first time,and now the bike is smooth,no tappet sounds and still dont know why SVC suggested a Cylinder Kit Replacement for this.

Special Thanks to PSR Sir and Sarin Bro [KB100] ,Sarin bro had done this before,but first time in a karizma,anyway he had done the best to help us.

Detailed pics and Explanation will come soon.

Thanks Aneesh for checking.

I went around the city looking for spares and luckily one stockist had the following:-

Parts procured:-
1. Chain sprocket (Rolon -good as OE)
2. OE Clutch cable and plates
3. OE Saree guard (chrome - don't ask me why I bought, just picked up for some mods).

Still looking out for:-
1. OE Battery box (cage) of older ZMA-R model.
2. OE Accelerator cable ( he had only type A, not B - so decided to wait when both available).

**ashwinprakas** · 10-05-2011, 08:57 PM

Originally posted by Aneesh@4GHz View Post

Enquired today,everything is out of stock here,luckily we got 2 tappet O-Rings,only 2 of them were left,we bought it.

and finally after spending one day adjusting and had some errors we are doing this for first time,and now the bike is smooth,no tappet sounds and still dont know why SVC suggested a Cylinder Kit Replacement for this.

Yup, A day well spent. Finally got a chance to understand how the engine works(atleast some of it.).

Special Thanks to PSR Sir and Sarin Bro [KB100] ,Sarin bro had done this before,but first time in a karizma,anyway he had done the best to help us.

Jai...Jai..PSR Sir...Jai..Jai....Sarin bro....And keep in mind guys, its always good to be friends with a person who's got a hell lot of experience & patience (Thanks sir, for being patient and guiding me through't the experience.) and a person who's a Mechanical Engineer, especially if you've got the DIY Syndrome.

Last but not least, my sincere thanks with Aneesh, if he was'nt there none of this would've happened. And I'd be riding a Splendor/Platina instead of a ZMA.

Detailed pics and Explanation will come soon.

Yeah will be out by midnight. Its actually not an instruction manual on how to set the valve clearance. Its an instruction manual on what all you should'nt do to mess up the valve clearance.

Originally posted by psr View Post

Hearty Congratulations .......So finally you and Ashwin had sucessfully done a D I Y of Tappet gap adjustment,which even the SVC dread to do....
Your effort is much more than my contribution,and full credit to both of you.
Keep it up...

The credits goes fully to you, Aneesh bro & Sarin bro. Cause without you'r help and co-ordination I'd be in one helluva mess. Once again my sincere thanks.

Originally posted by Aneesh@4GHz View Post

Thanks sir,Actually Sarin Bro done it,we had tried but failed and lost compression(Over Tighten ) after that sarin bro helped us,loosened it and showed us how to do it.But the T mark confused us a lot,its not working when its on the T-Mark.

When adjusted on the T-Mark,it sounded like a Sewing machine.

Yeah, we'd done it and lost compression. It was all thanks to Sarin bro's technical expertise that we got out of that mess.

Originally posted by psr View Post

what you found as "T" mark may be for setting the Ignition timing,which only the factory people will know,because a TDC mark cannot shift ,since the rotor is locked in place on the Crank shaft with a wood ruff key.

Sir, I believe its better we drop the "T" mark as guide when setting the tapet clearance, atleast in ZMA. Cause its way easier to set by trial and error methode.

Originally posted by SriramEfunds View Post

OE Saree guard (chrome - don't ask me why I bought, just picked up for some mods).

I'd say money well spent, cause the chrome saree guard's stronger than the black one that comes with the new bikes.

Replies in BOLD. Or atleast I think so.

**Aneesh@4GHz** · 10-05-2011, 09:04 PM

Originally posted by SriramEfunds View Post

3. OE Saree guard (chrome - don't ask me why I bought, just picked up for some mods).

Originally posted by ashwinprakas View Post

cause the chrome saree guard's stronger than the black one that comes with the new bikes.

+1^^ Me too ordered the old chrome one.

They are very strong than newer ones.

Also sarin bro told us to meet him tomorrow,he agreed us to teach us about carburetor and its cleaning or servicing etc.

I am Thrilled!

Originally posted by ashwinprakas View Post

my sincere thanks with Aneesh, if he was'nt there none of this would've happened. And I'd be riding a Splendor/Platina instead of a ZMA

When you asked me about that,I know how a Splendor reaches 100km/h and a Karizma reaches 100km/h.

Thats why i compelled you to go for the ZMA.

**ashwinprakas** · 10-05-2011, 09:29 PM

Originally posted by Aneesh@4GHz View Post

Also sarin bro told us to meet him tomorrow,he agreed us to teach us about carburetor and its cleaning or servicing etc.

I am Thrilled!

He also said he'll help me restore my Hyosung. And he also provided me with lots and lots of e-materials regarding automotive engine's and also provided me with a tutorial on building a bike from scratch. Thanks to him I have a true understanding of how my ZMA works*.

* I added the last sentence so the you know who's wont delete my post, guess I fooled them .

When you asked me about that,I know how a Splendor reaches 100km/h and a Karizma reaches 100km/h.

Thats why i compelled you to go for the ZMA.

True, and for all those who claim that ZMA's do above 125, then I believe its time they re'calibrate their speedo's. I know a ZMA does have the potential to do so, but not in stock condition. Im not talking about the BBK,FFE etc I'm talking about atleast swapping out the CDI. Cause the new CDI's with a limiter at 9.5k wont let you go past 125Kmph.

Replies in BOLD.

**Vishakh** · 10-05-2011, 09:29 PM

Originally posted by SriramEfunds View Post

Thanks Aneesh for checking.

I went around the city looking for spares and luckily one stockist had the following:-

Parts procured:-
1. Chain sprocket (Rolon -good as OE)
2. OE Clutch cable and plates
3. OE Saree guard (chrome - don't ask me why I bought, just picked up for some mods).

Still looking out for:-
1. OE Battery box (cage) of older ZMA-R model.
2. OE Accelerator cable ( he had only type A, not B - so decided to wait when both available).

One ZMA owner said that its very hard to get B cable

.

**kb100** · 10-05-2011, 09:41 PM

Originally posted by Aneesh@4GHz View Post

Enquired today,everything is out of stock here,luckily we got 2 tappet O-Rings,only 2 of them were left,we bought it.

and finally after spending one day adjusting and had some errors we are doing this for first time,and now the bike is smooth,no tappet sounds and still dont know why SVC suggested a Cylinder Kit Replacement for this.

Special Thanks to PSR Sir and Sarin Bro [KB100] ,Sarin bro had done this before,but first time in a karizma,anyway he had done the best to help us.

Detailed pics and Explanation will come soon.

it was a comedy of horrors ,setting the tappets , it will make a great read , especially about ashwin loosing his hair

had to make up special tools to solve some catastrophes that cropped up on the way , and thanks a lot psr sir for guiding us through the process

**ashwinprakas** · 10-05-2011, 09:46 PM

Originally posted by kb100 View Post

it was a comedy of horrors ,setting the tappets , it will make a great read , especially about ashwin loosing his hair

Yeah, I promised god that I'll go bald if my bike gets better.

And Sarin bro, dont forget, "The screw that screwed us" & "The nut that made us nuts".

**kb100** · 10-05-2011, 09:53 PM

Originally posted by ashwinprakas View Post

Yeah, I promised god that I'll go bald if my bike gets better.

And Sarin bro, dont forget, "The screw that screwed us" & "The nut that made us nuts".

yup the infamous "screw that screwed us" and the "nut that drove us nuts "

still cant believe that something so small can cause so much trouble

**psr** · 10-05-2011, 09:54 PM

First D I Y

Ashwin your words tell all about the first few D I Ys.....

Yup, A day well spent. Finally got a chance to understand how the engine works(atleast some of it.).

Sir, I believe its better we drop the "T" mark as guide when setting the tapet clearance, atleast in ZMA. Cause its way easier to set by trial and error method..

D I Y is not about the beaten path but about exploration into the unknown....The first few times it will be hard and frustrating,but if you pursue patiently you WILL succeed ......like you have now..
Best of luck on all your D I Ys.

**Aneesh@4GHz** · 10-05-2011, 09:56 PM

Originally posted by kb100 View Post

still cant believe that something so small can cause so much trouble

Yep,That was an unexpected trouble.

**psr** · 10-05-2011, 10:04 PM

Originally posted by kb100 View Post

it was a comedy of horrors ,setting the tappets , it will make a great read , especially about ashwin loosing his hair

had to make up special tools to solve some catastrophes that cropped up on the way , and thanks a lot psr sir for guiding us through the process

You are the man who understood and did the job...inspite of me

Originally posted by kb100 View Post

yup the infamous "screw that screwed us" and the "nut that drove us nuts "
still cant believe that something so small can cause so much trouble

So actually the nut screwed

Way back when i was learning, I kept trying to loosen the Primary gear nut by turning it anti clockwise while it should have been clockwise..Took one full day to understand..

**ashwinprakas** · 10-05-2011, 10:07 PM

Originally posted by psr View Post

Ashwin your words tell all about the first few D I Ys.....

D I Y is not about the beaten path but about exploration into the unknown....The first few times it will be hard and frustrating,but if you pursue patiently you WILL succeed ......like you have now..
Best of luck on all your D I Ys.

And Sir, I'll give my bike to SVC anyways to replace the cylinder kit. Cause its always better to get the parts replaced under warranty i.e in short FREE... Rather than crying over the lost opportunity after my bikes out of warranty.

**psr** · 10-05-2011, 10:11 PM

Originally posted by ashwinprakas View Post

And Sir, I'll give my bike to SVC anyways to replace the cylinder kit. Cause its always better to get the parts replaced under warranty i.e in short FREE... Rather than crying over the lost opportunity after my bikes out of warranty.

I wouldn't be surprised if the SVC says that your bike is alright and returns it as such.

**ashwinprakas** · 10-05-2011, 10:16 PM

Originally posted by psr View Post

I wouldn't be surprised if the SVC says that your bike is alright and returns it as such.

No Sir, they'll wash it before returning it.

You wont believe it Sir, but thats what they did the last time I went to set my valves. Me and Aneesh were shocked when the SVC guy said that the tapet was adjusted i.e especially when both of us were at the SVC the entire time watching over the bike.

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