Barricade - Yamaha FZ-16


Thread Starter #437
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January 2020

The bike started developing thud noise with feel from the steering column, so it's time for cone set replacement. Actually was planning to give to Muthoot Yamaha, but travel was an issue since no one was free to pick me to and fro. There was veteran Yamaha only mechanic 2 km away from my home, whom I visited previously for carb troubleshooting. Took it to him, explained the issues. He checked the bike and said so and so needs replacement. Left the bike and walked back home. Took 2 days to complete as the place was overcrowded with RXs. Called when work was over when I was at office. Reached home, parked Duke and took an auto. Reached there by 6:30, which time he was closing, but it was at his own cellar.

He replaced the cone set, fork oil and seals, clutch cable, ground the brake pads (which I asked to replace with old part number if available, but wasn't worn, but making noise as said in the previous post), properly bled the brakes and replaced headlight bulb (high beam conked off, which I never noticed as hardly use high beam). He also fine-tuned the bike, the timing, and chain and all. There was zero noise from the bike except the engine and horn. It rode smooth as well. Only thing I didn't like was the lavish use of grease, which was flooding from every joint, the issue with old school guys. Labor was pretty cheap too. He uses only genuine Yamaha parts and provides the bill for the same from the Yamaha dealer. Written bill provided for labor and rest of the miscellaneous parts.

Yamalube Fork Oil 10W (500 ml) - 90793-AD803 - ₹ 188.00 x 2
Race Bearing Kit - 5KA-W6619-00 - ₹ 225.00 (Crux part, cheaper and long-lasting than FZ. Seen this recommended by many guys) (Yamaha guys uses Libero part)
Clutch Cable - 21C-F6335-04 - ₹ 189.00
Brake Fluid - ₹ 38.00
Headlight Bulb - Osram Bilux 45/40W - ₹ 135.00 (Unheard of such a wattage, was running on 60/55W since ages)

Parts Total - ₹ 963.00

Labor - ₹ 600.00

Total - ₹ 1563.00

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Thread Starter #438
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January 2020 - Continued.

My boy was running fine after the service, but I could feel a sponginess when handle turned max towards right side.

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It was the improper routing of handlebar switchgear wiring getting in between the steering limiter. Thought of fixing it later during a weekend. But disaster struck when I jumped over an unseen hump. All electricals died.

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Forgot to keep the tools back in the bike after service. Again it was a Sunday and bad day to get stranded. It was a remote place and all available public transport were going for a political party event. Called everyone possible to bring a screwdriver. Walked 3km around that area in search for a screwdriver or something I can remove the screw with. After losing temper, pulled open the side cover with the plan of replacing it later, but it broke but retained shape so that I can repair it.

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Got access to the fuse, replaced it. Electricals came alive but refused to start. Push started. Rode home. En route had the balls to turn of and try again [frustration]
Cranking issue was actually the battery terminal getting loose.


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Punctured wire. Cut a bit and rejoint and sleeved.

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Found someone did this to indicator connector. Replaced with new bullet connect as well.

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Thread Starter #439
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January 2020 - Oil change

With Motul FS/SS price shooting sky, decided to stick with minerals as I would be changing in short intervals, max 2k km. Motul 3000 wasn't available, so bought Shell Advance AX5 20W50, ₹ 367.00. Wanted to try Castrol Power 1 Cruise, which was also not available anywhere as well.

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Late-night change as usual.

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Thread Starter #440
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February 2020

A good day's wash

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and inauguration of the Windek inflator. The tank sticker started peeling off.

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After using 60/55 for close to 10 years, lower wattage ones made night rides crippled. Searched for the normal cheap Phillips Premium, but no one had it. Came across this unheard Korean brand, Excelite. The extra 30% was what struck me and the shop guy assured it's a good brand. Google also said so.

Excelite H4 + 30% - ₹ 130.00


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The uprated HS1, which the mechanic installed. Osram Bilux 45/40W.


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The tab is what differentiates HS1 and H4.

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It prevents the proper installation of H4bulb in HS1 units tilting the bulb towards the bottom.

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Fold it down and it fits perfectly.

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Thread Starter #441
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February 2020 - New Front Tyre

With front tyre nearing replacement, bought a Pirelli Angel CT from Amazon.

Pirelli Angel CT 110/70-17 - ₹ 2,895.00.

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Matching rear tyre [angel]

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Pirelli

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Angel CiTy

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110/70/-17

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Can be installed in rear as well. Haven't seen such ones since the old import Michelins.

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Made in Indonesia.

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ISI certified.

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September 2018 make. Kinda new.

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Not radial.

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Rest of the literature.

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Thread Starter #442
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February 2020

Front sprocket was worn out and making noise. Had spare one from last time. Zodix brand.

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When removed old sprocket, shocked to see the disaster waiting to happen. The drive axle tooth almost wore out. Installed the new sprocket with the plans of getting it replaced next week after salary credit.

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Thread Starter #443
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March 2020 - and it happened

Salary got delayed, so did the plan. After a drag at the highway signal, and an outrun overtake in a steep road, finally, the drive axle gave way when I downshifted to accelerate further (Too much in love with the mid-range, crazy, but stupid). Lost the sprocket lock and bolt in the process. Happened in a busy, narrow single lane road. Managed to roll back without making a traffic situation. Was on the way to work, home is now 25 km away. Applied leave and called a nearby friend. By the time he arrived, checked reviews of all nearby mechanics and not even a single trustworthy garage anywhere near.

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Happened next day of Attukal Ponkala. The whole Trivandrum was in sleep mode except the BPO slaves like us. Getting a pickup was next to impossible. Finally got one after roaming 4-5 km around Kazhakuttom. Barricade's first tow in all these years of ownership. The guy was extra careful. Slowed at all potholes and humps and even used indicators for lane changing as well. Helped with loading/unloading as well. Took ₹ 600.00 for 8 km.


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It was an Atul-make pickup, rip off of Piaggio Ape. Space was too cramped for two. Not even space for helmet, had to put it behind.

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Gave it to Royale Yamaha, our old mechanic, but my least preferred place, but had no other option. A very skillful guy, master of almost all famous mechanics in town, but quality of work is nowhere good. Gave it there by 10 AM. Initially, TAT was next day evening. Sprocket cover was in my bag, so went there to give it by noon. Bike was already on the lift. They wanted to replace the chain set, do full engine work and clutch replacement since anyway they are taking the engine off. Said nothing doing, just the drive axle and bearings, rest all done some 20k km back. So the TAT changed, promised to deliver the same day evening, if and only if I'd show up in the evening for sure. Clutch had some tightness and lever had some play. Asked them to check that as well.

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Got call by 7 PM that bike is ready and they can wait till I can come. Reached there by 7:30, the bike was being washed. Test drove and to my surprise bike was at it's best since it left the showroom. Zero extra sounds from anywhere, butter smooth. Clutch was like a dream. (But I knew something will be wrong).

Parts:
Drive Axle Assembly - 21CE740250 - ₹ 728.00
Clutch Case Gasket - 54BE545600 - ₹ 63.00
Magneto Gasket- 54BE545100 - ₹ 40.00
Timing Gasket - 54B-E2435-00 - ₹ 23.00
Motul 3000 20W40 - ₹ 350.00
Front brake lever - 5YY-H3922-00 - ₹ 95.00
Clutch Lever - 5YY-H2911-00 - ₹ 125.00
Sprocket Holder - 4LS-E7456-00 - ₹ 7.00
Sprocket Bolt - ₹ 5.00
Anabond - ₹ 45.00

Total - ₹ 1481.00

Labor:
Engine Overhaul - ₹ 3,500.00
Wash - ₹ 180.00

Grand Total - ₹ 5161.00

Two authorized service centers were just a kilometer away, but bill would have been twice or many times more as they would replace more parts, but with a guarantee.
 
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Thread Starter #444
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And as expected issues started poping up day by day.

To start with, shoddiest wash with dirt all over and sprayed with some pungent-smelling fluid, which removed all the glazing of the bike and a dirt magnet.

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Missing paint. Also in air scoops. High pressure at point-blank. [frustration]

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Leaking petrol. New fuel hose. Pushed with the clips on.

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Straps of magnetic tank bag inside the tank panel. What was the dickhead thinking then? Other end was let loose, banging against rear footpeg. See the dirt and oiliness of on the tank, just the next night.

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Missing screws. I could track 6 till now. Replaced with brand new ones.

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Rubber cover of the timing chain adjuster missing, leaking oil through it and causing tappet noise like hissing sound. Cover not available separately, have to replace the whole adjuster.

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Loose nuts of chain adjuster.

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The steering column is now loose as well. Except for the smooth clutch and engine, there is noise everywhere. [frustration]
 
Thread Starter #446
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April 2020

Quarantine warmups.

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And as expected issues started popping up day by day.

To start with, shoddiest wash with dirt all over and sprayed with some pungent-smelling fluid, which removed all the glazing of the bike and a dirt magnet.

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Missing paint. Also in air scoops. High pressure at point-blank. [frustration]

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Leaking petrol. New fuel hose. Pushed with the clips on.

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Straps of magnetic tank bag inside the tank panel. What was the dickhead thinking then? Other end was let loose, banging against rear footpeg. See the dirt and oiliness of on the tank, just the next night.

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Missing screws. I could track 6 till now. Replaced with brand new ones.

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Rubber cover of the timing chain adjuster missing, leaking oil through it and causing tappet noise like hissing sound. Cover not available separately, have to replace the whole adjuster.

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Loose nuts of chain adjuster.

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The steering column is now loose as well. Except for the smooth clutch and engine, there is noise everywhere. [frustration]
and more issues popping up [frustration]

More missing bolts. Even from gear linkage.

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Sprocket cover. See the timing TDC window cover damaged.

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Oil leak from timing cover.

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Air scoop paint stripped due to point-blank high pressure wash.

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Petrol leak again.

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Misfitted sprocket cover spacer, damaging the rubber grommet.

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And the shittiest, disconnected (forgot to fit) engine head breather. Such a dick mechanic.

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And bike refuses to start like normal. It took umpteen cranks and pushing and ends up starting with thick white smoke and gave me heart attack. Oil level was low as well.
 
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Thread Starter #447
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Petrol leak eventually turned out to be the crap hose bought less than a year back during carb replacement. Not workshop guy's fault.

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It got cracked and split away. How can someone make such a **** quality fuel hose, how danger can it be it was running and hot. Just 7 months to be exact. OE hose lasted 10+ years without cracking.

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Replaced with better quality stuff, which was lying around for long. Looking for Yamaha OE hose, which no one stocks.

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Thread Starter #448
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Coming to oil leak, it wasn't the usual vapor leak, but oil dripping.

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Removed the timing window and there was no sign of any sealant used though was billed a tube of Anabond. Only residue of old sealant, which wasn't properly scrapped off. Gasket was new.

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Did a quick clean, but not thorough one since I have to redo it as the sealant I had was out of its shelf life and wanted much cleaner black sealant. The one I had was ThreeBond Super Sealer Clear Silicone Gasket Maker. Applied a thin layer on both sides and also the bolts and installed back. Hope it fixes the leak.

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Checked the sprocket install since they are famous for flying sprockets.

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Replaced missing bolts.

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Oil level is pretty low, just ran 300 km after the rebuild. It's at the low end of dipstick. It needs around 1.2 L since the entire casing was opened, then billed for only 1 L. Also per bill it was Motul 3000, but it was more grayish. AFAICR Motul 3000 was gold in cold. Skeptical about running on the one. Dilemma whether to top and run 1k km since I hate wasting oil or simply replace the oil and filter.

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Sticker started peeling off. Tried removing the residue, but glue is super strong. Gotta really mess with it. Sticker not separately available, so DIY stickers.

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Spare part shops and workshops are now open on Sundays and Thursdays, Stretched the walk to get the essentials to 2 km to get a can of oil as well. Wanted something in 1.1-1.2 L bottle to change the oil filter. Available options were Motul 3000 in 1.2 L and 7100 in 1.5 L. I knew Castrol Power 1 Cruise came in 1.1 L bottle and wanted to try since many were having positive response with it. Only 2.5 L was available. Bought it right away. Investment for a year. Can do oil change twice and with the current scenario, not gonna munch more miles.

Castrol Power 1 Cruise 15W50 - MRP ₹ 999.00, got for ₹ 980.00

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So many screw ups [frustration]

I had the exact same issue of tappet door leaking after getting the head decarbonised..and the mechanic didnt bother to replace gasket.
Had to change it out myself to get the leak arrested
 
Thread Starter #450
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So many screw ups [frustration]

I had the exact same issue of tappet door leaking after getting the head decarbonized, and the mechanic didn't bother to replace gasket.
Had to change it out myself to get the leak arrested
You might know this guy, Sydney. He will be there only in the afternoons and the kids work on the bike. He is a veteran in Yamaha bikes, but this kind of attitude spoiled all the goodwill he created over all these years. This is not the first experience. Whom ever I referred to this place has ended up in some issues. When we complain, he simply asks to bring it back, and he will fix it. A friend who lives nearby him says no one in that locality goes there.

This is their rice and kerosene. Why can't they do it properly? [confused]
 
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