Barricade - Yamaha FZ-16 (2009) - Midnight Black

[deville_56]

March 2022 - Exhaust Painting

Exhaust has been a sore part on the bike with the faded, rusty appearance.

Bought in September 2021 and painted in March 2022, thanks to commitments, laziness and back pain. Nippon Ryo Pylac 1000 Heat-Resistant Black Spray Can MRP ₹ 487.00, got ₹ 195.00 discount with effective price ₹ 292.00. Got from Santha Paint House.

Removal. One nut ant bolt near rear foot rest.

One bolt on either side of the exhaust underbelly.

Two nuts on engine head.

These two nuts are difficult to access. Only the 1/4 inch drive would fit (maybe the 3/8 too). 1/4 to 3/8 to 1/2 adaptation vs direct 1/2 inch drive

With everything unfastened and some wiggle, the exhaust comes off. Can be pulled out with some twisty moves.

Cover up the exhaust port.

Removed the covers.

Condition of exhaust. Dirt + tar + rust. No holes.

Started off with diesel and wire brushes.

Then with stolen wire sponge and vim liquid.

Ended up wet sanding with 400 & 800 water paper.

Once more vim liquid.

Painted two coats with 30 min gap.

Left to bake in sun for 3-4 hours.

New exhaust cover.

Old broken cover.

Old vs new.

Forgot to buy rubber grommets and spacers (again). Reused the old ones.

Ready to install.

The incomplete look. Electric bikes would sorely miss those.

Positioned before install. Chances of scratching is high, reason for installing the cover later.

Exhaust Pipe Gasket - 21C-E4613-00 - ₹ 22.00
Recommended replacing every time refitting the exhaust, but not mandatory.

Installed the gasket.

Hook up the exhaust port first

and align and install the rear bolt.

Install rest of the bolts and and tighten up and done.

Old gasket and carbon build-up.

Old ones were rusted, so bought new ones

and replaced later.

There would be fumes and unpleasant smell for some days till the paint bakes and settles down.

 

[mayankdixit]

That is a very neat painting job you did. Looking good. How is it holding up now?

 

[deville_56]

That is a very neat painting job you did. Looking good. How is it holding up now?

Holding well so far.

 

[deville_56]

March 2022 - New Handle Grips

Dirt in grip, prompted replacement. Last changed in 2017.

New grips.
Handle Grip RH - 21C-F6240-000 - ₹ 57.00
Handle Grip LH - 21C-F6241-000 - ₹ 42.00

Rust inside RH grip.

Cleaned and off.

Installed new one. Comparing old with new.

LH grip still looked new. New one had length difference. I can't make out old and new.

Installed. Getting it out is a bit tricky. Usually, would apply a thin film of oil for rust prevention, which causes a little bit of free rotation, but when the bar end is installed, it would be tight between the switchgear and won't rotate unless you wanna force it.

Bar end weights. Painted them. I liked their rounded edge compared to original Bajaj ones, so keeping them.

All done.

 

[deville_56]

March 2022 - Update

Thought of replacing fuel filter since it has been some time and felt it might have been clogged. Got Varroc fuel filter, ₹ 25.00 each. Bought one for Kiney too.

Got a magnet to catch metal debris.

Old Mico vs new Varroc.

Installed.

Someone tried starting and cranked till draining the battery. Failed to start on pushing. Checked air filter box because of strong smell of petrol. It was filled till the intake mouth with petrol, might have been sucked into the carb/engine as well. Cleaned the mess.

Knew it might need a hell lot of cranks, connected Beat's battery and it started in 4-5 long cranks.

Checked daily for 2-3 days for overflow and there wasn't any.

 

[deville_56]

April 2022 - Misc Updates

Replaced brake fluid at 2-year mark from last replacement.

It was in okay condition without any murk.

Used KBX. Made in Japan Yamalube bottle from last fill.

Cleaned up.

Bled the brakes fully. Took just 2-3 minutes.

Washed my boy.

Yamalube PEA Carbon Cleaner - ₹ 163.00. Added to sort out the mild missing issue and it did.

Out for a night spin.

 

[deville_56]

June 2022 - Updates

Indicators have been sagging for some time and finally drooped with rubber stay tearing. I've been trying to source the stay for quite some time. Yes, Yamaha has child part for even indicators. Part number 5YY-H3318-10 for flexible one and 20P-H3318-00 for sturdy ones. As expected, all shops were interested in selling full assembly only.

Tried even with the Yamaha parts distributor, who said the part hasn't been ordered at least for quite a long time and no chances of getting them anytime soon. Found some in my indicator bin, which were from the non-genuine ones bought for my first LED conversion.

Removal.

A screw and plate hold the stay in place.

Replaced some fused LEDs.

Assembled back and fitted the new stay.

Installed. Brighter than most.

Need two more for the front. Found a couple of them listed in Safexbikes.com, both original and Swiss brand. I'd order them if I can't find two more in my bin.

 

[deville_56]

June 2022 - Avoidable Mishap (Expenses)

Usually, I'd park on the concrete surface, but with laziness to move the Beat and the ZMA, parked down on mainstand. With rain all night, woke up seeing my boy lying on his belly. Could've been easily avoided

FZ handle is known for taking the impact on falls, ended up buying new handle bar.

Got it from Moto Spare Tech, who ordered it for someone else.

Handlebar - 21C-F6111-01 - ₹ 380.00

Level difference.

Installed.

My brand-new exhaust cover also took the toll . Forgot painting the washer after sanding, which also started showing its shade. No other damage apart from a minor scratch on the front fender.

 

[deville_56]

July 2022 - Buffed Levers 2.0

I was making love with Momos and noticed (the Nth time) I am missing my buffed levers. Old ones were replaced when there was play due to oval'ing.

Stock look.

The right side.

Undo the nut first and then the bolt and the lever is all yours.

The left side.

Repeat the same,

but need to undo the clutch cable.

Started off with 80 grit,

then switched to 100 as 80 was too abrasive and causing deep scratches and 400 for finishing.

After some elbow greasing.

As always, forgot about the stuff in the closet, the paint stripper

Removed the rest with the stripper and trial finished with 400 grit.

The other side with the stripper applied.

Cake walk. Paint peeled off with gentle scraping.

After stripping and light sanding.

Installed on bike

and started the final cut.

Ta-daa.

 

[ThankaN ChettaN]

Am a big fan of your enthusiasm, has been following your thread since 4 yrs back, keep up the good work manam also from Trivandrum

 

[ThankaN ChettaN]

Aneesh Muhammad: (from Trivandrum)
+918848038348
Bro keep this contact saved, may get handy
He'll do all kinds of speedometer works (dials fadeout, kilometre resetting, led works and chip level)

Recently I got my Fz's speedometer repaired, didn't had to buy a new one

 

[deville_56]

Am a big fan of your enthusiasm, has been following your thread since 4 yrs back, keep up the good work manam also from Trivandrum

Aneesh Muhammad: (from Trivandrum)
+918848038348
Bro keep this contact saved, may get handy
He'll do all kinds of speedometer works (dials fadeout, kilometre resetting, led works and chip level)

Recently I got my Fz's speedometer repaired, didn't had to buy a new one

Thank you, thank you,

Where is he located?

 

[ThankaN ChettaN]

Thank you, thank you,

Where is he located?

Google Maps

@Kazhakootam

 

[ThankaN ChettaN]

TVS-Girling DOT4 Brake Fluid. 250ml, got for 80 Rs.

View attachment 143608


Fill and pump.

View attachment 143609


Till it's hard.

View attachment 143610


Speedo sensor. Before cleaning and lubing.

View attachment 143611


Old versus new. Pirelli Sports Demon and Michelin Pilot Street. Both 110/70-17. PSD was still grippy and good for another 2-3k km.

View attachment 143612


Michelin is way heavier than Pirelli.

View attachment 143613


On the way to tyre installer.

View attachment 143614


After install.

View attachment 143615

View attachment 143616


Initial review is it's damn heavy but awesome grip. Corners as if there is some track laid for us.

View attachment 143617


Final look of steel braid.

View attachment 143618



In the interim, fork got overhauled after being screwed by a roadside mech. Also rear brake bite was less, all the shops were giving RX series brake liner for FZ, which will wear out soon and not at all efficient like stock. Rear brake overhaul was also done outside at SVC. Both jobs done at Essco Yamaha. Had to change fork cap bolt, which was also screwed by the roadside mech.

Bill amount:
Parts:
Brake Shoe Set - 296
Fork Oil Seal (one side) - 180
Fork Oil (1 liter) - 740
Fork Bolt Cap x2 - 198

Labor:
Fork Overhaul - 240 + tax
Brake Shoe Replacement - 100 + tax

Turnaround time was good. Gave at 9 AM, got back by 12 PM.

TVS-Girling DOT4 Brake Fluid. 250ml, got for 80 Rs.

View attachment 143608


Fill and pump.

View attachment 143609


Till it's hard.

View attachment 143610


Speedo sensor. Before cleaning and lubing.

View attachment 143611


Old versus new. Pirelli Sports Demon and Michelin Pilot Street. Both 110/70-17. PSD was still grippy and good for another 2-3k km.

View attachment 143612


Michelin is way heavier than Pirelli.

View attachment 143613


On the way to tyre installer.

View attachment 143614


After install.

View attachment 143615

View attachment 143616


Initial review is it's damn heavy but awesome grip. Corners as if there is some track laid for us.

View attachment 143617


Final look of steel braid.

View attachment 143618



In the interim, fork got overhauled after being screwed by a roadside mech. Also rear brake bite was less, all the shops were giving RX series brake liner for FZ, which will wear out soon and not at all efficient like stock. Rear brake overhaul was also done outside at SVC. Both jobs done at Essco Yamaha. Had to change fork cap bolt, which was also screwed by the roadside mech.

Bill amount:
Parts:
Brake Shoe Set - 296
Fork Oil Seal (one side) - 180
Fork Oil (1 liter) - 740
Fork Bolt Cap x2 - 198

Labor:
Fork Overhaul - 240 + tax
Brake Shoe Replacement - 100 + tax

Turnaround time was good. Gave at 9 AM, got back by 12 PM.

Bro, how did you clean the speed sensor, can we use petrol or turpentine inside the sensor, will it damage? Could you explain how you cleaned it up?

 

[deville_56]

Bro, how did you clean the speed sensor, can we use petrol or turpentine inside the sensor, will it damage? Could you explain how you cleaned it up?

Any solvent would do, even diesel, or WD40 would be fine. Spray or use some cotton waste soaked in solvent and wipe out the dirt inside, which would be primarily old grease + dust mixture. Clean it completely and apply some grease, and it would be good for reinstall. Sensor has only a rotating plate exposed and rest all sealed properly, so no worries of any damage. If the plate has too much play, the sensor might need replacement sooner or later.