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The story begins November 29, went down to the basement and I got on my bike and that sad feeling of monotony and adjustment that one gets when they get used to stock power, a sadness overcame me, and I knew there was only one solution, to poke and prod as much as I could and squeeze every last pony out of my 220. Got on the phone with Joel and asked him if we could get the once the fastest Indian to take her title back, the familiar confident and fun sounding Joel was enthu and so was I, I took around a month from Jan 5th to get the funds ready and on the 4 of Feb the work began #ProjectUhura was born.
Day 1 (Feb 3).
Arrived from Chennai at the ungodly hour of 1130 PM, no work was to be done today :P
Day 2 (Feb 4).
The bike was stripped,
oil drained (700ML remained) and smelled so burnt o.O 300V Fail.
Went through the various mods to be done
, inspected all the parts, shiny new straight from the packet 
.
List of Mods and other parts that needed replacement :
1. Big Bore 230CC, Mild comp with a domed piston.
2. All out totally bombed Head with ported and polished head and intake manifold.
3. Bigger carb With A butterfly and not a slide.
4. Simota Free flow filter cone type.
5. Free flow (version 2) Full Stainless exhaust.
6. Jet upgrade to size 130 with some tuning (needle adjustment).
7. Cam Chain.
8. Cam Chain Tensioner pads
9. Motul 5100 SS
10. Clutch lock nut (counterclockwise locking)
Day 3 (Feb 5).
Assembly of all the parts and work on the revised head was started and completed after no less than 2 hours (Just the head), work installing all the parts was started at 12Pm and finished at 8, the carb was running a heavily lean tune at mainjet size 117.5.
^Amount of material removed from the head.
The head.
^Re-Assembly.
^Final Piece
Day 4 (Feb 6).
Back to Joels shop to upjet to size 130. Bike ran a bit hot last night due to break in and the lean tune, so with the upjet should run better more fuel = a cooler engine and safer burn as compared to a lean one, then by 1230 same day with some minor tuning I was of to the N.I.C.E road to go up and down and break in the engine with slight increments in Rev limits.First 100 kilometers it was 5000 RPM, then from 100-250 it was 5500, further 250-400 it was 6500 RPM and then I changed the oil and slowly climbed the rev range, a slightly hard break in, but I feel it was best. Throughout I did small upper rev range bursts, for minimal time, as heating and cooling would help it (personal opinion and personal experiences are yet to say otherwise).
Day 5 (Feb 7).
Feb 11th
Update, at night while tooling around the Thiruvanmiyur beach I went to pull the clutch to shift down and the lever was harder than the brake lever. Shocked I pulled to the side, and went through all the possible faults, and then started kicking myself for not changing the clutch when I should have, the extra stress probably pushed it to breaking point. Limped the 230 back home and crashed out.
Feb 12th
Woke up and got on the bike, forgot the clutch was buggered, and decided to ride the bike without the clutch LIKE A BOSS. So pushed the bike till about 5kmph while the engine was on and in neutral and dropped into first at around 5 kmph and from then kept quick shifting up and down :P. Went to BAJAJ ASC, and they said they could give me an appointment on Friday so I took it, and made sure he had the parts in stock (Clutch assembly full, gasket, and Oil {Motul 7100}) and rode back home the same way :O.
Feb 14
^Image of spark plug shows the perfect burn.
Day 1 (Feb 3).
Arrived from Chennai at the ungodly hour of 1130 PM, no work was to be done today :P
Day 2 (Feb 4).
The bike was stripped,
oil drained (700ML remained) and smelled so burnt o.O 300V Fail.
Went through the various mods to be done
, inspected all the parts, shiny new straight from the packet .List of Mods and other parts that needed replacement :
1. Big Bore 230CC, Mild comp with a domed piston.
2. All out totally bombed Head with ported and polished head and intake manifold.
3. Bigger carb With A butterfly and not a slide.
4. Simota Free flow filter cone type.
5. Free flow (version 2) Full Stainless exhaust.
6. Jet upgrade to size 130 with some tuning (needle adjustment).
7. Cam Chain.
8. Cam Chain Tensioner pads
9. Motul 5100 SS
10. Clutch lock nut (counterclockwise locking)
Day 3 (Feb 5).
Assembly of all the parts and work on the revised head was started and completed after no less than 2 hours (Just the head), work installing all the parts was started at 12Pm and finished at 8, the carb was running a heavily lean tune at mainjet size 117.5.
^Amount of material removed from the head.
The head.
^Re-Assembly.
^Final Piece
Day 4 (Feb 6).
Back to Joels shop to upjet to size 130. Bike ran a bit hot last night due to break in and the lean tune, so with the upjet should run better more fuel = a cooler engine and safer burn as compared to a lean one, then by 1230 same day with some minor tuning I was of to the N.I.C.E road to go up and down and break in the engine with slight increments in Rev limits.First 100 kilometers it was 5000 RPM, then from 100-250 it was 5500, further 250-400 it was 6500 RPM and then I changed the oil and slowly climbed the rev range, a slightly hard break in, but I feel it was best
. Throughout I did small upper rev range bursts, for minimal time, as heating and cooling would help it (personal opinion and personal experiences are yet to say otherwise).Day 5 (Feb 7).
Feb 11th
Update, at night while tooling around the Thiruvanmiyur beach I went to pull the clutch to shift down and the lever was harder than the brake lever. Shocked I pulled to the side, and went through all the possible faults, and then started kicking myself for not changing the clutch when I should have, the extra stress probably pushed it to breaking point. Limped the 230 back home and crashed out.
Feb 12th
Woke up and got on the bike, forgot the clutch was buggered, and decided to ride the bike without the clutch LIKE A BOSS. So pushed the bike till about 5kmph while the engine was on and in neutral and dropped into first at around 5 kmph and from then kept quick shifting up and down :P. Went to BAJAJ ASC, and they said they could give me an appointment on Friday so I took it, and made sure he had the parts in stock (Clutch assembly full, gasket, and Oil {Motul 7100}) and rode back home the same way :O.
Feb 14
^Image of spark plug shows the perfect burn.
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