Barricade - Yamaha FZ-16

Thread Starter #421
Sep 11, 2009
September 2019: Continued - Brake overhaul

No-brainer-job first. Replaced the caliper and split pins. Just pull out old one and put in new one and lock with pins, just gotta be careful the pads don't fall off.

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Empty the brake fluid.
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Wipe it off the paint surface ASAP, in case.

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Remove the bleeding screw. Keep a cloth to trap any residual brake fluid flowing out.

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Old bleeding nipple. Rusty and blocked.
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New nipple in place.

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Now replacing RC kit. Remove the lever and then the pin..

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Royally screwed. Reverse bleeded the system. Installed back everything. Called it a day.
(Filled from the Minda bottle to save the Yamalube)
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Thread Starter #422
Sep 11, 2009
September 2019: Continued - Brake Master Cylinder Overhaul

Borrowed cir-clip pliers from @varunkumar2910

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Drain the brake fluid, again. Less than a week fresh brake fluid [frustration]

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Remove lever and the pin.

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Access the cir-clip and remove it with the pliers.

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Remove the piston.

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There would still be fluid in there. Pay attention not to spill over paint.

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Removed piston.

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Old vs new pins. That's flaking paint from an old quick botchy paint job.

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Pin is rusted and rounded causing longer strokes, needing extra effort. Just for this replacing the entire kit.

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Pistons - old vs new. Piston is in good shape.

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Cir-clips - old vs new. Except the dirt, it's also good as well.

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Bybre make. Some specs, which even Google didn't return any info.

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Hole through which fluid flows to and fro.

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Fix the spring and install the piston. Spring goes in first.

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Piston's rubber part will get stuck in the hole. Push down with something and it goes in freely.
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Install the cir-clip. It will fit in this position only if master cylinder is not removed from bike.

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Install the new pin.

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My favorite weapon. Mastered reverse bleeding. Did 3-4 times in last one month. Pretty fast and efficient. Needs less fluid and will take just a minute or two.

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And that 3-4 times did this as well [frustration]. Don't forget to cover the reservoir. Wipe off ASAP.

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Position the lever and install it.

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There would still be air trapped in it with freshly installed parts. You can simply remove some fluid with a cloth and continue little bit more of bleeding. Or it will escape itself with pumping a couple or times or with regular use.

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Fill to level. Close the reservoir. Done.

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Thread Starter #423
Sep 11, 2009
September 2019: Misc jobs

The screw story:

Brand new MC cover screws when installed in mid July.

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Condition in mid August

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Condition in September.

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Bought Bajaj OE screws. Should be original Bybre.
Bajaj DE191030 - ₹ 4.80 x 2

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Old vs new. Previous one was bought from a non-authorized Yamaha service center.

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Wanted steel one from Dominar, but spare comes only in black per spare guy.

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Painted handle (again)

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Bosny Grey Primer + Metallic Black + Flat Clear.

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Side cover OE Allen bolt was lost at one of the service center visit. Replaced with locally available Allen Bolt. Condition of it after the monsoon.

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Replaced them with star screws. ₹ 6/piece.

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New bulb holder's blue color is too prominent and looks odd.

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Thread Starter #425
Sep 11, 2009
New tyre: Pirelli Angel CT 140/70R17

Been a fan of Pirelli tyres since a long time. This is the third Pirelli model I'm using. Bought it from Amazon for ₹5000.00, just a week before price dropped to ₹ 3970.00 [frustration]
It's nylon tyre and likely replacement for the outdated Sports Demon. Tyre was heavier than Diablo Rosso and felt more plasticy than rubber.

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The reason why I didn't wait for the price drop or any Amazon sale. Wear accelerates just after a certain age. It was still grippy and holding well, even in rain, which is why I preferred it over MRF (know it's riskier to use racing slicks [lol])

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Angel CT

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140/70-17 M/C 66S
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Made in Indonesia.

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All the fine prints.

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2017 make, 37 week. Should be mid September.

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Lightest spot of the wheel.

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ISI certified.

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Thread Starter #427
Sep 11, 2009
New tyre arrived in September last week itself. Due to super-heavy work schedule had to run on the bald tyre for some more days, 3 weeks to be precise, until one day it started fishtailing when I turn towards right, not even hard leaning.

Ran exactly 23409 km in 675 days.

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Ran home slowly and took it to tyre guy. Cleaned the rim so as he wouldn't show angry face touching greasy dirty rim.

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and it rained as everytime.

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Usual chap.

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Brake dust. Brake shoe slightly misaligned due to work brake cam. Added to to-buy list.

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Installed and good to go.

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May 16, 2014
Its looking damn good I must say.Its enhancing the bikes look.
I am already a sucker for tyres and stuff,and you bought the best brand.Love it.Well done.
I was only worried about the age as already mentioned.
Thread Starter #429
Sep 11, 2009
Aren't the tyres a bit old? Although they don't look so. I mean its already 41st week of 2019.
2017 is comparatively newer. Expected life should be 5-6 years, anyway would replace in 2 years max. Hard to find better bike tyres in fresh stock. CEAT is the official importer of Pirelli and most of their stock is 2017. Private importers get newer tyres, but they charge exorbitantly. Nearing 2020, the 2017's price will fall even further. They want to sell off before it's too late and tyre shops won't accept old stocks. Win-win situation for dealer and poor souls like us [evil]
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Thread Starter #431
Sep 11, 2009
October-November 2019:

Bought Motul 7100 from Amazon, this time 10W50. Got for ₹ 636.00. MRP ₹850.00.

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As usual, it rained.

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Got it washed.

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And changed the oil.

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Love the red colour and smell of 7100.

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Got air filter as also.
Air Filter - 21C-E4450-00 - ₹ 225.00

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Religiously change it at 10k km, earlier depending on condition.

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Condition - New vs old.

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Bought brake cam, which was worn out. Would be replaced with next brake shoe change.
Rear Brake Cam Shaft - 36L-F5351-00 - ₹ 56.00

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Thread Starter #434
Sep 11, 2009
November 2019: My boy turns 10.

Still my daily runner, averaging 40 km a day.

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Clocked 142k km.

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Birthday special wash at Florence Car Care. First time in 10 years with such a thorough wash.

First a high-pressure wash.

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Then diesel wash and degreasing.

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Soaked with foam.

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This guy was doing from the heart.

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Rinsed with pressure wash.

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Wiped dry. ₹ 300.00, less than 20 minutes from start to end. Three guys working on it. This place was recommended by @varunkumar2910

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Back home. Silencer needs repainting.

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More love. Meguiars. Compound + Polish + Sealant

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My boy.

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Dwarfed by the newbie of the gang.

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Thread Starter #435
Sep 11, 2009
December 2019: Rear Brake Overhaul.

Rear brakes are the most dissatisfied part amongst FZ owners. Many say it lacks the bite and makes a lot of noise. I have a mixed experience. Noise is often from brake dust or moisture in it. Coming to braking, it's low when new brake shoes are installed and starts biting after it's seated properly. But after all, I noticed a weird wear pattern, not at all consistent. The usage pattern is the same throughout and situation also similar, but life varies very much. Was so jobless that made the chart below [lol] Best of approx 17934 km to worst of 5774 km with a total average of 10188 km, but lately only 8000ish.


Brake Shoe Set - 1GCF530K00 - ₹ 281.00
Generic part for all 130 mm Yamahas.

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and consists of a set of two.

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Each has its individual part number and made by ASK. 5YY-F5341-00 and 5YY-F5331-00. Non-reversible.

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Springs. You have to buy them separately. Again, both are different and not reversible. No need to replace them every time. They are reusable.

Part numbers 90506-15001-00 and 90506-12001-00. ₹ 3.00 each.

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And they make a set.

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Rear Brake Cam Shaft - 36L-F5351-00 - ₹ 56.00
(Posted previously, saved for next brake job)

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Ready for install.

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Pipeline work aftermaths.

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Top brake shoe grinding against wheel drum wall.

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Damage inside.

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Complete disassembly.

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Worn out brake cam. The suspected cause of brake show play.

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Old vs New. Slight length difference.

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Cleaned up everything and installed the cam first

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and then the shoes and rest of them.

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All set and last wash of 2019.

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Another wrong part, saved for future. Asked him specifically for rear one and gave front instead despite showing the parts in the parts manual, but couldn't confirm part number as it was version 2's manual. Will replace the next time I remove the front wheel.

Wheel Collar (Front) - 21C-F5183-01 - ₹ 28.00

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