this week has been very tiresome and daunting .
my alter bike was running awesome . but suddenly I got the urge to open it .. the urge was created by the new bizarre piston that I had bought for it . MAX100 0 Number piston . this bizarre piston was 53mm and mine was using 52.4mm piston . this piston was domed shape and had valve relief and was slight higher then the 52.4mm flat top piston .. the advantages of fitting this piston were numerous .. I had bought it long ago but had kept it for free time ..
on Monday I opened my bike head and cylinder and took those two things to Muhammadi Kharadia .. Committee chowk . I had earlier talked to him of the work that I will do and he had said its doable .. .. I took both head and cylinder .. first was boring the cylinder for the piston . which was promptly done . then looking at the finished product I was not satisfied as it had mirror like smooth look .. so I asked him to hone the cylinder fro excellent criss cross shape .. they said its four stroke cylinder and it needs mirror finish .. contrary to what I have seen and heard ..
thought they gave it some criss cross shape but not satisfactory ..
then came the widening of the ports .. I wanted to widen the ports and remove any imperfections there due to casting .. they just inserted a big drill bit and carved a hole out of it .. and that left a big bump in the valve .. they said its ok .. we have been doing it like this for ages .. rubbishing all the literature and knowledge in the open domain .. hahahha..
i later using drill machine and mounting stones removed those imperfcations that were caused by them ..
then came the head . I wanted to slightly increase the outer surface of the chamber combustion area .. because the new piston was slightly taller and needed more piston top to head relief . I also wanted to slightly deepen the already there outer area .. the result was a disaster .. their machines were ffffff or the man were ffff .. whatever the case be the result was a total disaster ..
they carved a big dish like surface out of that teeny tiny chamber .. and also widened the chamber to the extent that it touched the stud hole ?.
See pic below for the details..
Then I came home tired and when fitted all the things my bike wont start .. which I initially suspected ..
Now I again opened the head/cylinder and found the chamber filled of engine oil .. so I came to know that this head is kaput ..
I am really pissed because this was one such awesome head .. it never needed to adjust valves before 5-6k and was doing awesome job..
Now I was faced with two ways .. either use the 110cc cylinder with max100 piston and the stock head (dhoom stock head .. 78c bikes stock ) . but this would give obvious problems of piston hitting the head as the stock head chamber was very small..
Before putting the stock head .. i was faced with another dilemma .. its intake valve was bent .. though at the time of removing it from the stock bike .. there was no issue .. or may be I haven't had checked properly .. but I only noticed it after cleaning .. so what I did is opened the destroyed head and removed all of its parts (tappets/valve(only intake)/springs/camshaft) .. and then opened the stock head and put all those parts (thanks God at least the parts were interchangeable .. thus minimizing the damage ) ..
So after the stock head was ready .. I fitted it onto a 110cc cylinder coupled with max 100 piston.. I fitted all the components .. and gave its flywheel a small turn only to find that the piston is hitting the head .. I was using fiber gasket .. so wanted to give it another try .. I this time used another set of head gasket .. this one is metallic one .. which has four metallic sheets ..
Sadly I still faced the same issue ..
In the meanwhile I also found that my stock head spark plug threads are also stripped ..
So now I took my stock head to a nearby kharadia in Islamabad in peshawar more .. yousaf kharadia .. for the thread repair . he inserted the bush .. and since this head was using one vlave form the other head . so I thought to buy new set of valves and re lap them according to this head .. so bought new valves sets ISH Malaysia .. and had the kharadia re lap it .. In the mean time I had packed the old valve sets in the packing of new valve sets and forgot them at the kharadia shop .. only to know the other day that the kharadia said we threw anything left .. :?(
When I reached home I found that the spark plug bush that was fitted was dinga .i could hardly use the plug pana to fit the plug .. as it would touch the plate on the head .. so Iremoved the plate on the head and inserted the plug .. (I had removed all those parts before taking them to the shop . had I not removed them it would have been easy to get this problem caught at the kharadia shop any how. Somehow I had fitted the plug.. but it was impossible to fit the cable as the connector wont go there .. so i had to do a temoprary jugger .. later i took the bike to kharadia and using grinder he grinded the fins on the plate to allow for easy removal of the plug and installation of the cable .. whch was earlier not possible.
here is the pic illustraitng the consequence of dinga plug bush.
Now after fitting the plug I was realy pissed up .. as the plug was hardly visible inside the combustion chamber? these karadias said its normal .. and will work ..following are few pics fo the new plug bush installed and how it looks inside ..
anyhow after a lot of troubled swinging b/w kharadia and home i fitted it all in stock condition.
Now I am partially stock.. after 3 days of khwari .. a head going gutter due to monkey headed mechanics .. who are only good at doing things that are done repeatedly .. not at something new ..
Bike is ok but defintley nothing compared to its altered state..
MORAL OF THE Article:
1 => Never think high of the desi mechanics .. and kharadias . they are only good at doing things that are done repeatedly and don?t need any mental processing . anything that is new to them .it is bound to be destroyed by them. As neither they have the tools and knowledge to do any intricate task .
2=> for those who would be doing this type of work be it in normal case or modification case do keep these in minds .
3=> the reason for sharing is .. well sharing is caring .. caring about self and others