Ok, if that's the case, then let me share what I experienced.
Never go in for conversion & its better to get the complete 5 speed assy instead. Before the build, I can vouch to touch 70 Kmph in 3rd for sure (may be upto 80 as I vaguely remember this) & 90+ in 4th. Hope this helps.

Here's the latest update on my gear shift problem

• For the first 2-3 Kms there's nothing wrong & one can hardly notice any issues in the gear shifts & its only after these many Km's (probably engine getting warmed up/heated up) these issues are cropping.
• Once again, downshift from 5-4 is same butter smooth
• Shifting down from 4-3-2-1, I've discovered a method as how to avoid the hard presses or gear slips. Yes gear is slipping between 4-3 sometimes to false neutral & sometimes to 2 or sometimes never downshifts & stays in 4. What I need to be doing is, after shifting down from 5-4, I need to slightly, very slightly upshift; consider this shift up like a feather touch too, then I'm able to shift to 3 normally.
• After shifting to 3, once again the feather touch treatment to be done, otherwise, I'll run into false neutral or stay at 3 & will never go for 2nd gear.
• This morning one more new issue cropped during the gear shift from 4 to 5. I step up to 5, but still 4 is engaged unless I press it real hard. This is not again a continuous pattern, but occured just 2-3 times in the morning 30 Kms ride.

I don't know if I need to be meddling with cylinder assy & crankcasing to fix this issue. I'm more worried on opening the cylinder & piston. Guys, any idea what should I be looking at? Any help is highly appreciated.

Now whats the gear box set up like ?

1) existing 4 spd g box added a 5th gear.
2) or a entire g box is new with drive shaft and axle ?

Psycho - Everything spankling new - no juggad work; its 2

what all did u change ? changed drive shaft too ?

@Psycho - its difficult to say which is new; in simple words, except the disc brake setup, front headlamp, clutch wire, clutch lever, clutch side rubber cover, all other parts are brand new. When I say new, that means the mud flaps from the rear to the front mud guard, every single item is new. Its like a brand new motorcycle coming out of the home instead of factory.

dude i went through all u r msg can't wait to see u r bike put some pics man

Thanks for going through the thread; I guess you need to revisit this post on pics.

500 - better late than never

Clocked 400 on Monday evening on the way to the regular fuel pump; 500 on entering into office campus yesterday. As I write this, the ODO clocked about 560 odd Kms.

The gear shifts are biggest headache till now, neither I haven't been able to take it to mech nor he's able to come down to check. But, its not as serious like last week like stranding in the middle of road blocking the traffic, may be the issues are clearing or may be I've adjusted to the issue. There's a false neutral between every gear is for sure & these false neutrals are not to be seen in the cold engine.

Since Y'day I'm revving the engine little in each of the gear, however waiting to cross 50 Kmph mark after 600 or so. Its like this...
1 - between 5-10
2- upto 30
3 - upto 40
4 - upto 50
5 - Maintain 50-55

600 & then 700-800 in one shot

Keeping the post short & simple...
600 clocked near L&T Infotech Porur
700 clocked just before Mathuranthagam
800 clocked at entrance of Chennai bye-pass at Tambaram end

Current reading on ODO - 828. For people wondering (esp Raghav & Undefineme) how I managed...
Started at 4:15 AM from home this morning, made a to & fro journey upto Achchirapakkam which is just before Tindivanam & back at home by 9:00.

Was itching to cross 700 so that I could pick up some more speed. Finally when I crossed 700 & started speeding between 60-70. To be frank, here's the readout:
619 - At home started at 4:15
723 - At Achchirapakkam at 7:00
829 - At home at 9:00

Made a rigourous test from 741 to 801 in 59 minutes; the engine contained still the same heat & I could touch the cylinder head bare hand for a second or so & the casing for about 2-3 seconds. This was the same case when I checked at ODO 700.

So this makes me feel that the rings have got adjusted to the cylinder in position. Last evening, I adjusted the gear pedals to stock position & as of now I'm keeping my fingers crossed & not commenting on the gear shift; let me run for another few 100 Kms & post the updates here.

dude put more oil in petrol .. even if u using u r side box put a additional 1 oil along with petrol if not put 2 oil ( this is for 1 lit) it gives out more smoke dont mind .. this smoothen's u r piston an chamber .. this is how i did it for my rx .. do this for 2000 km then u r engine is set...

Wow nice suggestion there, so how much oil you run per litre 50ml ??

whats 1 oil/2 oil? 100/200ml? this smoothens the chamber??

Ok; Thanks; will follow.

Lol

Pradeep, appologize for posting the pics of spark plugs late; here're they...











Pls comment on them