Sorry, had been busy today. Will let you know tomorrow.

As you all are aware that my bike was having a short circuit problem well seems like it is fixed now. The shorting was coming from inside the instrument console. I didn't think of that even in my wildest dreams. I had checked every other wiring with multimeter and inspected every joint in the wiring finally got fed up and installed a 20A fuse in place of 15A. And when I pressed the starter button fireworks and smoke came from beneath the console . And from that moment on the bike is behaving normally. Well it showed neutral when I was riding in gear but going over a few potholes solved that. Expecting the problem to surface up soon I am not at all going to the SVC as they messed up the wiring and it was an untidy job. So I am planning to open up the console myself with the help of the parts catalog and senior members here.

Bro, first inquire whether the console in under warranty. If yes, I believe you know what to do next.

BTW, got a call from Diya while I was on my way back from Palakad, they're done with my bike and requested me to pick it up, so will be doing that tomorrow evening, just hoping they didnt mess my ride.

ZMA-R 235 cc

ZMA-R 235cc on road as on 10 April 2012 . So far so good ! Since my daily run is limited , updates may be slow in coming . I hope the updates will be all positive !!!

clutch plates

how to check the cluch plates are in good condition or not?
one of my mech rode my bike and said the clutch plates are gone so u should change them as it could create further problems in engine?
so how to check it?
i didnt feel any difference in pick up in the bike.
the bike has clocked around 8k kms on the odo and running on honda 20w40.
and else all is bone stock...

well yes a leg guard is a must and it really sves your bike from scratches as till now my bike has humpty-dumpty 3-4 times and always in parking all the time by other ppl fault but my bike got no scratches from the fall till now here is the pic of leg guard installed without the engine cowl removed .
it was a matter of some welding and direct fit



pics are not very clear but i believe it has been discuss on forum before about installing leg guard

Wow..Keep on updating.

You will definitely feel power loss and clutch slip if the clutch plates are worn out.

Congrats sir!! Even I'm eagerly waiting for updates. Is there any run-in required?

Thx , sure will .
Finally , after some hair tearing - head banging on wall wait , it's on the road . It purred for the first time in the 235cc guise at @ 7.30 PM and was puttering home (some 25 km away) at @ 8.30 PM .

Thanx to psr for his valuable inputs .

Also it was thanx to him that I had to ride home at below 50kmph . He had asked me to maintain engine speed below 3k rpm for the 1st 50 km and then below 4k rpm ( or was it 4.5k, I have to clarify it from him) for the next 50 km .
When 100cc commuters and scooters and even mopeds zipped past me (- a big person riding a big bike , wearing a big helmet ) I could only mutter in my mind - every dog has his day - & - my day will come - !!! I'd have gladly paid someone to take that ride for me , on the other hand I'd never think of giving that 1st ride to any one else . The power difference was evident from the in-gear speeds . I didn't have to down-gear much .
Today I took leave - all that standing at the workshop had put some strain on my back . Lay down with medicine applied for @ 3 hours , then a quick bath and I was off . I visited one of my colleagues at his office and lunch was on him . By then the 3k rpm rev limiter was off and I was going upto 4k rpm . The speedo showed 65 kmph @ 4krpm and the GPS says that the top speed I attained was 67 kmph - so I'd mostly stayed under the limits . The increase in power is more evident now , but I had to let go of subtle invites from an RTR and a P220 on some twisties - not that I normally do that .
I've set 200 km and then 400 km as check points for increasing engine speeds . Have to change the oil during that period . My mech had put in 10W30 and I'll be changing it to 20W40 .
In 2 weeks I expect the old model CBZ silencer to be with my mech . That's the next change .
The best part of it is that my original cylinder/piston is untouched . The mod was carried using a 2nd hand cylinder and a P220 oversize(25) piston . The cyl head I used mine as it was more costly . The piston had to be modded slightly as the gudgeon pin seating hole was bigger . It was done using a brass rod . The head gasket had to be ground to size for the increased dia . No other major mods were done .

Will post snaps ASAP .

http://s1117.photobucket.com/albums/k597/acs1207/ZMA-R235/?action=view&current=235a.mp4

Thanks shhbz ... seeing the number plate on your bike; i think you had done it in WesT Bengal... but i need to do it in Bangalore..

So i need Bangaloreian BHP helps..

Accelerate hard and take a particular note in the RPM, if it suddenly shoots up without the bike accelerating then your clutch plates are worn out. Another way would be to check if your ZMA does the same speed as other ZMA's in respective RPM's. i.e 80@5K etc.

How come the bike didnt start at first??? And why didnt the mech bother to use the kicker???

And sir, the engine note of the bike is quicker and less heavier than usual, was the idle increased or anything???

@Everyone.
Today got back my bike. Didnt get time to inspect her throughly. All I know for now is that, the bikes running on 10W30 HH oil.

The bike didn't fire at first 'cause the engine was starved of fuel . The carb was near empty and the fuel line had an air lock . When it started , the choke was on and after he shut off the choke , the rpm was maintained high and was brought down gradually .
Frankly , Ashwin , would you get up on a ramp and try to kick start a bike ????? I know I wouldn't . Also , he knew I had 9 Ah battery . BTW , why the emphasis on using the kicker ? I've never used it , even in December . I just use choke and the starter . I've read about kick starting being recommended for morning starts , but never could fathom why . Care to enlighten me ?

Have run 80 odd kms so far after being 235 . There's heavy knocking when I wring the throttle in top gear while going @ 55 kmph . I suspect high compression ratio inspite of using 3 gaskets . Anyway it's a job for post run-in .

2 or 3 dead kicks and starting the engine with kicker will be better for longer engine life.. Well this is applicable if the bike has not been used for like 6 hours or more. Hats off for the mod. It will be very valuable data for us here who are planning to go for engine mods.

well i know but its very easy if you know a good mechanic a total of fitting and guard cost me Rs 350 in total as they fixed some clamp to make the thing fit , i forgot which bike leg guard matches the same like that I will try to post pic to clearly make u understand how its done and than u can guide the person if anything is done wrong

reply also in bold/maroon .

Thanx - willing to give details to any one who's doing it .
( edit: and it doesn't cost the earth-or a ship-or a flat in a metro- or a plane ticket to Dubai !!!)
BTW , I'm hoping this is just a beginning!