@Roughseas- Is your bike the one which was launched in India a decade ago? I remember these bikes used to have a charging unit problem and people used to get either the RD or RE one to get going as OEM was quite expensive and hard to get. But a very sweet bike to tour with plenty of power to spare. But I don't remember the twin headlight set-up. Did you got it done later? Love the set-up though, one for short/wide through and another for long.
For you upgrades, you can tune the front suspension by just playing around with fork oil level.
Yeah the rear shocks is a must upgrade for C5 along with the bushes from Hotchcocks. A must upgrade is the swing arm bushes to CI ones even if you are not planning any mods.
Best and cheap mod is to go for carb, I think it will also eliminate rev limit unless the TCI unit has the limit pre-programmed.
@Nasir- A little while ago the spitfire helmet was available at 50% discount for around 12k including shipping. If you have anyone going to UK then you should get one. It even has a similar c green colour matching the bike
REgarding your 4th service, I recommend the following which are must;
1.Change the fork oil
2.Get the T cone bearings inspected and greased, probably replaced if they are rusted. It could be the cause of your bike pulling to right. (if replaced Under warranty then savings of Rs500)
3. Get the front brake fluid changed (Rs 80 for oil)
4. If you are still on OEM supplied rear brake pads then you have made them last a decade. Our bikes get the smaller pads from factory and the ones you will get from service centre are a inch longer and provide better braking due to larger surface contact area. (Rs 250)
5. Get the rear cushion rubber pads replaced. They will help you getting rid of any shuddering you might have felt during braking and get rid of dead play which you might have felt when you apply brake and the rear wheel still rotates around a inch.(Rs 90)
6. Get the rear drum bearings and hub bearings checked along with the front hub bearings as well. If the rear hub bearings are fine then don't bother to get them greased as for greasing them, they need to be removed and once removed/greased they don't last long. (drum bearing Rs 150)
7 .Front pads wont be covered under warranty I think ( Rs300) They will easily last 30k but if you feel the necessity then do the needful. It wont be easy to get the disc replaced by them. "Remember" the moment your bikes crosses 10k, even if they diagnosed a problem with the disc under 10k but if they haven't got the disc in by the time you have crossed 10k. They will quite politely refuse you a replacement. Do the needful
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Tell them to check according to the service manual and check for run out. If they cant check the run out technically then its their incompetency and their problem. Insist on a replacement then.
8. Get the CI bull bushes and they have to be shaved a wee bit, just few mm.
9. For the fuel line, they wont have it in stock. Better not to get a new one from them as it will again develop cracks within few months. Better to get a fuel line from any car manufacturer and replace it. Although it's a two layer pipe but why to take chances hey.
10. Get the wheel aligned and spokes tightened. The spokes on my wheels were loose at just 5k.
11. Get the rear shocks pressure checked. should be around 100Psi
12. Get the auto chain tensioner checked, for that they will have to remove the LH side cover to inspect it properly.
13. If they can get the engine compression checked and if above 140Psi then get the head de-carbed. Although according to their manual it says to de-carb if above 110Psi.
14. Change to fully synthetic only if you intent to do some hard riding and can change at every 3k. I suggest to keep the stock oil and get oil changed every 3k. You should see the colour of engine oil at 3k. It should not be kept till 6k.
But if you want to then go for Motul 300V 15w50 grade. It comes in 1L packing and you need 3L. Engine needs only 2.3L. Its around Rs850 per litre.
The above to do list is must and worth only if you will be there while servicing, otherwise it will never get done. Most time consuming is fork oil changing and Tcone greased.
Lot of Indian cars have same size piston or bore of 84mm so one can check out the specs and see if any engine have 86.9**mm size and same deck height+ few other matching parameters then one could try to make it work on C5 while making the bore to 87mm. Although a very possibility is to find the 535 lightening piston and go with that but I think the design of the oil rings on the piston is different to the C5 piston oil ring.
@Naren can you shed some light or info on the 535 piston rings design or a picture so we can compare? I think you had re-built a 535 of you brother in-law.