Bike feels free to rev and gives better FE, without much heating up.AFR screw 3.5 to 4 turns depending on the set up you want..3.5 turns moderate acceleration with 32 Kms city FE. 4 turns for good acceleration with 31 Kms FE.

Yes but you have to wait for Fevibond to dry fully otherwise the suction inside the Air Box when you accelerate, will pull the glue in..which is why I used Hot glue ,which heals immediately.
For the petrol tank cap there is a vent hole to be cleaned..
It is the hole at the lower left corner in the Petrol cap..After removing the white one way valve in tank cap you can blow air through it and see if it comes out through the lower hole in tank cap.


It is a pink foam i had around which is used to block the Gap in the side...planning to fill it permanently with plastic piece.

Yes thank you.
Intake sound does not change..but the ZEN MPFI filter makes air breathing better than stock.....none of the Allenkey screws will give any access to the exhaust inner..To access either catcon or the baffles the exhaust must be cut open

If you look at the stock Karizma filter and the ZEN filter, the first distinct difference is the size of it, and also the pleats in the paper. The OE ZMA filter has many close folds ,almost sticking to each other,which itself restricts air flow even when slightly loaded with dust.In the ZEN filter the pleats are wide apart allowing larger square area which is open to air.Inlet re-rooting either before or after filter is not required...there is a resonator in inlet to take care of resonance of inlet air pulses.

No difference in air inlet noise and, yes none of the Allenkey screws will give any access to the exhaust inner..To access either catcon or the baffles the exhaust must be cut open .
No need to drill holes in the airbox..this had already been discussed earlier in this thread.After fitting in the ZEN filter securely without leaks,use it like stock air filter without any other mod.
I had done 2,300 Kms and yet to take it out and clean it...I live in the heart of city in a place close to the arterial road connected to National highway and a Large Bus stand..Last week the air pollution board's check certified my area as the most polluted in the city...but the bike still doing well..will open the air filter sometime later to-day and post a picture later.

Guys here is the Karizma Spare Parts Price List Google Doc,When you open it it will sent a request to me,I will accept it.

Suggestions and comments invited.

Calculated the total cash spend on maintenance of my bike from the first day of purchase and it totaled to 9900rs,major expense was Disc Pad 2200rs and Engine overhaul 2000rs. Balance was oil changes,services,some part replacements on accidents etc. Excluding current accident.

OMG, no no not so much tools with me. Great mechanical project that would be, cutting and drilling and welding. Thanks by the way.
I was just wondering if I can remove some DB killer ...??? (Will it work?)

Don't worry bro, this depends also on the cover(glass or plastic cover) over the headlight. Me and my bro both installed the same bulb(Philips Xtreme 55/60 w) and his bulb was appearing to be more "white" than me, later I inspected that his headlight cover was very new and clean compared to mine as his bike was relatively new. I washed my cover many times but could never match the "white" quality of his bulb. But its okay

Don't you think Sir, that this filter is allowing impurities to the carb more than the stock filter?

I think you are more confused than before.....to know the present /original setting of AFR spray WD40 on the AFR screw,wait 15 to 30 minutes and see if the screw turns without trouble.Then turn the screw CLOCKWISE GENTLY,and keep count of the number of turns, till it stops and cannot be turned further.The number of turns you counted now is the actual setting you have on the bike...make a note of it now someplace safe.From this fully tight position turn the screw ANTI CLOCKWISE to the same number of turns as before,and you are back to your previous/stock setting..simple isn't it !
How do you presume that the ZEN paper filter allows impurities into the air inlet ?The design of stock ZMA filter is such that it is small in size and the pleats are sitting on each other thereby presenting a closed surface to air inlet. The ZEN filter is larger and the pleats are more open to air inlet and so allows BETTER permeability..This filter is made of paper pulp which is what the best air filters are made of...and meant for a 1,000 cc engine...or 4cylinders of 250cc each..imagine what will happen to engine if the air filter were to allow more dust in to the engine.
Request you to do some reading on the basics of Carburetor,and Air filter types and their filtering efficiency....

Correct Sir, but what i feel is the mileage wont increase until the bikes running lean. The air flow will surely be better at high RPM's due to the better flowing characteristics of the zens filter.

Even with the resonator at its place wont changing the intake route which has many tuns & twists improve the flow of air ?? (keeping the stock air filter)

The choice totally depends on what one actually wants out of his bike/engine & at what cost.

For revising the air intake you need to take many points into consideration.
Trust me but drilling holes wont do any good

You will get slightly more air inside the engine & the mileage will increase due to lean mixture formation (not healthy for the engine in long run)

Forced induction not possible.Even if experimenting the cost will land up in the price range of say ninja 250 or more.

I would like to know your goal with the engine first & your budget ?

I had gone for the ZEN air filter because the OE was not available...FE was not the reason..
Regarding intake route and length, ZMA has a slightly circuitous route to take advantage of it's low end torque. A longer inlet gives better low end,and will prevent throttle surges during closing of throttle...the Helmholtz resonator takes care of standing wave pattern to give more linear acceleration.
Most commuter oriented vehicles ,looking for good low to mid end and hence better FE always use longer inlet manifold with Resonator....

@ALL ,
I had noticed Another difference between the older and present 2011 ZMA in the RR unit..The present RR looks bigger and runs cooler than the older smaller version..here is a pic of the 2011 RR in ZMA-R.

Here is a picture of the ZEN air filter in my ZMA after 2,300 Kms..
front view..

Back view

Intake area


Inside box..note the clean inner against the dusty and dirty inlet to the right side...The Zen filter is doing an excellent job..Note also there is no blow back oil at the floor of the box...probably due to the 20W40 oil I use.

And i thought the zen filter was being used for increase in performance

Well i have done my research on the intakes but not as deep as you.Variable lengths & resonance do help in filling air inside the cylinder during suction stroke.Now time to see how it helps with linear acceleration.

Would like to have any related links if possible.

From my experience in doing some design and implementation of Resonators, in vehicles the most near correct resonator design(for low RPM.) for closed volume control was equal to 30% of total volume of cc required to fill the space....for instance if there is an engine of 1500cc with longer inlet manifold, then the starting point for resonator volume will be 500cc plus or minus 10%..for higher RPM the resonator will be smaller in volume to suit the specific resonance....Resonators basically cancel out strong resonance caused by bouncing waves from sudden closure of intake valves during intake cycle,by absorbing the return energy,and adding it in the next intake event to give better volumetric efficiency.This effectively cancels null points at certain RPMs and actually give better cylinder filling.This is why in most naturally aspirated modern cars there will be more than one resonator in the inlet manifold.

Replies in BOLD, and thanks everyone for the speedy reply.

Mainly from the carb and a small proportion from the filter.

Ashwin,You checked the price list?

Oh nice to hear the Kiney thingi stories here. You have a very good sense of humor.

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