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

[deville_56]

As far as I remember, the last time I swapped the hose, I measured the stock one at 31.5 inches (80cm). I’m guessing the Pulsar hose is 75cm, which is why it’s a tight fit.
So far, the 85cm hose is only available from RCB, but unfortunately, that doesn’t come with rubber grommets. I had a very bad experience buying from Amazon, one seller shipped the wrong size, and the other hasn't shipped yet. Given this, I’m now thinking of buying and importing from AliExpress instead.


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Check in local accessory shops too. I have seen many in Cochin and way cheaper than Amazon, around ₹450 (I got from Amazon for ₹599 then). Same generic hoses. Not sure about length. AliExpress won't deliver to India nowadays. Rarely some seller do, but at high shipping rates and will definitely get caught by customs, who'd slap another 60-70% as duty. Not worth unless shipping to some other country and bringing in person by some acquaintance.

 

[ansh240]

Check in local accessory shops too. I have seen many in Cochin and way cheaper than Amazon, around ₹450 (I got from Amazon for ₹599 then). Same generic hoses. Not sure about length. AliExpress won't deliver to India nowadays. Rarely some seller do, but at high shipping rates and will definitely get caught by customs, who'd slap another 60-70% as duty. Not worth unless shipping to some other country and bringing in person by some acquaintance.

Already tried in Karol Bagh, and none of the shops there have the right length. The only exception is Moto Planet, which has RCB hoses for ₹2,399, but those come without rubber grommets.
Regarding the import, the only option I have is to order them to my client’s address, and he’ll ship them to me. But since the shipping cost is quite high (3k via Aramex), I’ll have to order 5-6 hoses to bring down the average cost.

 

[ansh240]

UPDATE

Finally found right length (80 cm) for just Rs 250 in Karol Bagh. Went there to grab a fork rod T and oil seal driver. On the way back, I saw a superbike mod shop and thought, let’s ask one last time. And the guy straightaway told me not to ask anyone else and pointed me to an unnamed shop in a narrow busy street. To my surprise, that little shop had all kinds of hoses.
Most of the hoses they had were DOT certified, but I’m not sure if that’s the real deal or just for the name.

 

[deville_56]

2023 August - Fork Oil Leak

LH fork starts leaking.

Went to Muthoot Yamaha for parts. Their labour ₹ 280 x 2 + tax. Turnaround time a day or two depending on the rush.

Bought the stuff.

Fork Oil - Yamalube - 90793-AD803 - ₹ 188.00 x 2
Recommended 10W. 500 ml bottles. Each fork needs 459 ml.

Fork Dust Seal - 4EB-23144-00 - ₹ 299.00
Bought only one. Only one was damaged, other side replaced not so back.

Like always, Ars-HTA brand. Would be some ₹60-70 in their packing.

Model 7794.

Fork Oil Seal - 2GS-F3145-00 - ₹ 356.00 x 2

Again Ars-HTA.

Model 7705. Only ₹65 in their packing. Yamaha charging 5.5 times the original rate (so do RE).

Special Washer - 20P-F3418-00 - ₹ 11.00
For steering. Damaged by the previous guy.

Race Bearing O-Ring - 90202-26142 - ₹ 2.00
Which the previous guy didn't install despite providing new one.

Took to KR Motors for fork seal replacement. Didn't have the tools, should get them soon. Youtube mechanics showing crude ways without proper tool, which I never would wanna try.

Job done.

This is what he is famous for.

Perfect job.

His best stance.

 

[deville_56]

August 2023 - Misc Updates

Grabrail paint gone the Nth time. Needs rust conversion.

Stripped the paint.

And redid.

Ready to install.

Oil level alarmingly low. Something is no right. This was after 1.7k km since last oil change.

Topped up with Yamalube FS. Took 450 ml to the top of the dipstick.

No fouling of the plugs.

Not much blowby in the filter box.

Atrocities of the old school mech. Replaced the caliper bolts with wrong sized ones with a couple of washers.

And abundance of grease everywhere.

Bought a pair of bolts from Yamaha.

Flange Bolt - 90105-10319 - ₹ 40.00 x 2

Original size vs what he had used.

New bolts in.

Chain nearing its end.

 

[deville_56]

October 2024 - Throttle Cable Replaced

Throttle was hard and getting stuck. Since there are umpteen iterations of cables, have to note down the part number for the correct part.

Accelerator Cable - 21C-F6311-10 - ₹ 230.00

The ends.

Suprajit make.

The culprit.

Old vs new.

Done.

 

[deville_56]

November 2023 - Insurance Renewal

Renewed with Acko

Basic Third Party Premium - ₹ 714.00
Own-Damage Premium - ₹ 300.00 (₹ 150.00)
NCB - 50%

Total Premium including GST (18%) - ₹ 1020.00

 

[deville_56]

November 2023 - (Finally) Engine Rebuild

Something wasn't right ever since the drive axle job (aka the messup) by Royal Yamaha. Tried two places to get things right, but some issue remained. Main issue was, in case of a shut down during cold start idle, bike won't start, needs choke and sometime pushing to get it through. Then, this oil depletion. No burning or leak or blowby, but it's disappearing. Found a new garage, Jixie. An "over educated" enthusiastic guy. He did the rebuild, but wasn't satisfied himself and tore down again to find the root cause. It was a bent decompression cam causing the trouble. New one wasn't available at Yamaha. He sourced a used one. Did the job again. Outcome was great. Normally, FZ would take a good 7-10 feet in 2nd gear for a push start. He demonstrated a jerk start in 1st gear. Settings were that perfect. Gave a demo on the run-in process. Also repaired the starter motor, which was overlooked by many over these years. He used modified Pulsar brushes.

Engine on his bench.

He works a single bike a day (or a stretch).

Jixie.

New cylinder kit.

Parts:
Cylinder Kit - ₹ 2,788.00
Timing Chain - ₹ 364.00
Decompression Lever - ₹ 200.00
Exhaust Valve - ₹ 260.00
Gasket Set - ₹ 160.00 x 2
Head O-ring - ₹ 74.00
Valve Stem Seal - ₹ 88.00
Air Filter (Varroc) - ₹ 230.00
Spark Plug (Bosch) - ₹ 130.00
Rocker Arm - ₹ 340.00 x 2
Consumables - ₹ 200.00
Diesel and Petrol (Cleaning) - ₹ 200.00
Petrol - ₹ 200.00
Starter Motor Brush - ₹ 114.00
Sprocket - ₹ 78.00

Labour:
Valve Setting - ₹ 500.00
Engine Parts Water Service - ₹ 100.00
Labour - ₹ 3,000.00

Total - ₹ 9526.00

 

[deville_56]

December 2023 - Misc Updates

When you take alternate routes when you can reach home otherwise in 10 minutes

Visited the spare shop for some Karizma parts and he was sorting FZ parts and saw the wheel hugger. Price was dirt cheap than anticipated. Got one right away. Old one had fading and had striae.

Rear Fender Comp. - 21C-F1650-00 - ₹ 150.00

Needed cleanup before install.

More than anticipated.

Took to the nearby wash.

Cleaning was thorough,

but they missed out the greasy bit. They don't use diesel.

New vs old.

After installation.

Spark plug installed by him. Bosch R6. Not a fan of Bosch plugs. The itch starts for the NGK plug.

Model UR3DC.

Old ebay.in cover used for tool kit.

Night at work.

 

[deville_56]

December 2023 - Running In Complete

Took back to Jixie for valve clearance readjustment after break-in.

Oil Change + Valve Clearance Setting - ₹ 500.00
Oil + Filter - ₹ 400.00

Total - ₹ 900.00

Oil was Castrol 20W50 mineral oil. Valvoline 4T Champ 20W40 mineral oil was used during the rebuild.

 

[deville_56]

December 2023 - Chain Sprocket Set Replacement (and the associated chain of replacements)

The current chain sprocket set had clocked almost 40k km and started making noise. Always ran on Rolon sets (OE and non-OE). Spent a premium and got the Brass Kit.

Rolon Brass BPR Kit - NXRC 231 - ₹ 1,916.64 (MRP ₹ 2178.00) + ₹ 175.00 Shipping.
Got from SAP Motors, Indore as the kit for FZ-16 version was unavailable with most sellers at that time. Ordered just relying on their Google reviews. They sent it promptly.

The rear sprocket is finished in black and the front is zinc and the highlight of the kit being the brass chain. The inner sprocket is fine blanked and the rear is induction hardened (their own wordings).

Started off. Chain sprocket replacement needs a lot of cleanup and on inspection might end up replacing parts like the swingarm bush and wheel bearings. Most garages would simply ignore even the cleanup part and just go ahead with the kit replacement alone.

Condition of the chain slider rubber. Dirtiest bit.

Damper Clutch aka Cush Rubber - Steelbird RX03 - ₹ 107.00

Rolon Chain Lube - ₹ 160.00
Just to keep the chain clean till the freshness is gone.

The air pressure sticker fell off.

Cleaned up the swingarm.

Swingarm bush and bearing removed.

Rusty, but intact. Initially thought of cleaning and reusing, but my brain won at the spare shop.

Bush stressed on one side.

The oil seal wasn't replaced in over 10 years due to nonavailability. Ars-HTA 7250

Swingarm Bush - 21C-F2184-00 - ₹ 50.00 x 2

Swingarm Bearing - 93317-318Y5 - ₹ 253.00 x 2

NRB DB182416P. Only ₹60 in NRB packing.

Finally got the swingarm oil seal.
Swingarm Oil Seal - 93109-18803 - ₹ 20.00

All swingarm parts together.

Installed the bearing and seal with some anti-seize.

Bush slides in.

Removed the monoshock collar and lubed and reinstalled. Most of the bikes have them seized into the shock absorber due to ignorance.

(To be continued)