Barricade - Yamaha FZ-16


Thread Starter #331
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The original template cut years back

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Prototype 1 begins.

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Version 1. Squeezed up 56 LEDs. Not so perfect soldering, regular Solderon soldering iron plus impatience and hurry.

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October 2018:

Afterthoughts. Version 2.

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2.1. Adds 4 more LEDs. 52 LEDs total.

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Blacked out background. Yellow tinted for the perfect amber and the yellow shade (see final ones).

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The base.

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10W load resistor, integrated to the unit. No more extra connectors and dangling wires. Replaced the 470 ohm unit with a 150 ohm later, need an even lower value.

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Finished units. V1 and V2.1, each.

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Thread Starter #333
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Painted handle. Matt metallic black. OEM finish.

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New horn. Minda K90. Hyundai i20 OEM. ₹ 440.00
Replaced Bosch Symphony for milder sound. Might fit that back.

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Low tone.

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High tone.

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Installed at previous locations, inside tank on either side.

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Thread Starter #334
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Center stand bolt had fallen off, missing nut. It's 12 mm head and thread size of 14 mm bolt. Most bolts in the bike are googly like this.

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Main Stand Flange Bolt - 90105-10319 - ₹ 33.00
Bought 2 of them.

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Nut was not in stock, so got 14 mm flange nut. ₹ 5.00/piece.

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Front brake light switch was faulty, with light ON almost all the time.

Front Stop Switch Assembly 21CH398000 ₹ 80.00

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Old vs new. See the worn out head of the old switch.

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With connector and cover removed.

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Simple plug and play, if you intend using old connectors.

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Thread Starter #338
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Renewed insurance with New India. Total premium ₹ 2,206.00 for IDV ₹ 18,221.00. Huge bump in third party premium compared to last year.
 
Thread Starter #339
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Time for some carb cleaning. Some intermittent hiccups and red warning light glowing at lower rpms.

First got hold of the 3M carb cleaner. Paid some 240, a bit old stock, but chalega.

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Getting the carb off the bike is pretty easy. Remove the left side panel. Disconnect 2 cables and fuel hose and TPS connector. Loosen the hose clamps on either side and slide it out.

FZ-16 comes with a Mikuni carb, not sure about the model name. Part number is 21C-E4901-10.

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Dismantled. Used proper sized screw drivers and did not screw up like last time.

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Bowl not as dirty as expected. Some 70k km worth of dirt.

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Throttle Position Sensor

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Diaphragm cover.

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Dirty carb.

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Jets and all. Not dirty at all.

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Butterfly
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AFR screw with spring

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Carb slide and the infamous scratches. Not even 10% of the scratches the previous one had.

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Used the cleaner vigorously. It was indeed good. Dirt was flowing out even without using any force.

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Main Jet. #112.5.

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Pilot jet. #15.

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Float.

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Float needle and pin.

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Made in Japan. #Euphoric

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All set and done.

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Cleaned externals and installed back. Used the carb cleaner here also, made it easier than WD40.

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Thread Starter #340
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Birthday Wash

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Motul Chain Lube after a long time.

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From Birthday run.

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Same day lost the other center stand bolt.
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Had extra set bought previously.

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First thing done reaching home.

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Thread Starter #341
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December 2018:

Oil time. My favorite. Motul 5100 15W50. New 2018 stock. Made in Vietnam like 2017 batch. Paid MRP ₹ 540.00. Got from neighborhood shop, Spark Automobiles.

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DIY as usual. Got 850 ml of 5100 on 3k km of use, which is way better than alarmingly low volume of Yamalube full synthetic every time.

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Spark plug condition.

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February 2018:

My Boy

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Removed to lube the swingarm. The amount of dirt accumulated.

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Did a thorough clean up.

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Spanking new

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Some part:

Clutch Lever Boot - 20PF6372000 - ₹ 11.00

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Sprocket Holder - 4LSE74560000 - ₹ 10.00
Sprocket Holder Flange Bolt - 950270601000 - ₹ 2.00

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Clutch Lever Adjuster Bolt - 901230804600 - ₹ 20.00

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Throttle Cable - 21CF63110000 - ₹ 233.00
First model FZ had extra long throttle cable, later ones won't fit.

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(Some local vendor)

Clutch Cable - 21C-F6335-03 - ₹ 133.00

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Thorough wash after changing cables.

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119k

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Installed back the footpeg feeler. Removed it long back as folded jeans was getting stuck. Change in habits.

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Now it someone asks how is the Diablo Rosso.

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Would simply show this [evil]. This is with mild roundabout cornering. Metzler like leech grip or even more.

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Gave bike to Riders Garage, the same guy who fixed all the issues with PowerPig. Listens to the customer, understands and fixes every single problem. Wasn't expensive too. Barricade had unresolved tak sound from rear since delivery, asked every time at SVC as well as previous mechanic. He fixed it. Front brake calipers slids out of spring, which I tried fixing multiple times, which also got solved. Brother is planning a 1k km trip, so did not want to take risk with chain as it was making lot of noise. Changed it as well. Changed long due rear wheelbearings. By the by, gave him primarily for clutch overhaul for the trip.

Total bill: ₹ 3450.00 including parts and labor.

Approx parts breakup
Chain kit - ₹ 1,425.00
Damper Clutch - ₹ 100.00
Brake shoe kit - ₹ 306.00
Rear wheelbearing kit - ₹ 280.00 (3 pcs)

Oil and clutch plates provided by me adding another ₹1050.00 approx, making total ₹ 4600.00.

Jobs done:
- Engine reset. (Timing chain and valve install done previously was horrible).
- Valve clearance (A bit loosely set now, climbing rev easily).
- Clutch overhaul (60k on previous set).
- Chain sprocket (Did only 22k km on previous set, changed for trip, forgot to pick the old one).
- Rear wheelbearing.
- Brake shoes.
- Caliper issue fix.
- Tune up.

Bike is now butter smooth. No rattling or annoying sounds even dashing potholes. Accelerates really well, the best ever. Now happy in 60-70 range, no transitional vibrations. Tried 100, does without drama. Mileage back to 42 kmpl with a bit hard revving.

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Any finally wash + detailing.

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Meguiars Ultimate Compound + Tech Wax 2.0

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Just after chain sprocket set replacement, is it necessary to lube it immediately, or we can use it for some kilometres and then lube as required? I did the same DIY taking your awesome thread into reference, I must say you have done a great job maintaining the beast.
 
Thread Starter #343
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Just after chain sprocket set replacement, is it necessary to lube it immediately, or we can use it for some kilometres and then lube as required? I did the same DIY taking your awesome thread into reference, I must say you have done a great job maintaining the beast.
Thanks man.

Most chain comes prelubed, the white greasy texture. No need to lube immediately, but no harm doing so.
 
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Thanks man.

Most chain comes prelubed, the white greasy texture. No need to lube immediately, but no harm doing so.
Hey! Thanks for the earliest response. I had kept the chain with factory lube itself and it's performing decently.

I am also confused for spark plug replacement between Bosch Twin electrode U5 and NGK G-Power. Are the twin electrode spark plugs really better than single ones as they have better combustion capabilities? Have you ever used it?
 

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Thread Starter #345
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Hey! Thanks for the earliest response. I had kept the chain with factory lube itself and it's performing decently.

I am also confused for spark plug replacement between Bosch Twin electrode U5 and NGK G-Power. Are the twin electrode spark plugs really better than single ones as they have better combustion capabilities? Have you ever used it?
Never used the Bosch. Many were complaining of overheating issues with it. Been using G-Power since almost the same year I bought the bike. Bike cranks easily at any cold temp comparing stock. Apart from that nothing really noticeable. It's maintenance free. Fit it, forget it. No cleaning or gap adjustment needed.
 
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