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


Joined
Jun 3, 2020
Messages
13
Likes
5
Location
Kerala
This is exactly the same as my current petrol tank cap. In the new one the part marked with green is plastic (white colour). But the holes marked with red are missing. So I can confirm this is a manufacturing defect. The current leaky cap is Minda make. New one is spark. Deeply appreciate your post. Very very helpful. I'll get my new one replaced. Thank you. Screenshot_20201115-121857_Samsung Internet.jpg Screenshot_20201115-122229_Samsung Internet.jpg
 
Thread Starter #512

deville_56

Honoured Member
Joined
Sep 11, 2009
Messages
2,971
Likes
4,806
Location
Trivandrum
This is exactly the same as my current petrol tank cap. In the new one the part marked with green is plastic (white colour). But the holes marked with red are missing. So I can confirm this is a manufacturing defect. The current leaky cap is Minda make. New one is spark. Deeply appreciate your post. Very very helpful. I'll get my new one replaced. Thank you. View attachment 283212 View attachment 283213

My new one had the hole in the black plastic. Didn't check the inside one.

2019-07-25 21-15-47.jpg


(Spark is the new branding for Minda)
 
Joined
Jun 3, 2020
Messages
13
Likes
5
Location
Kerala
My new one had the hole in the black plastic. Didn't check the inside one.

View attachment 283214

(Spark is the new branding for Minda)
Yes this is an important set of air passage holes (I think it's called breather holes (not sure) ) without which petrol will not flow out from the tank. This is a one way mechanism which doesn't let petrol evaporate out from the tank but lets air in. This is a most often overlooked part. If this is clogged even partially, it affects top end performance. Although I noticed the difference between the new and old ones, initially I thought there could be some changes due to design revision so that the holes could be located elsewhere in the new one. Also the seller was obstinate that this could not have ant defects as it's Genuine Yamaha since all Genuine Yamaha parts come quality checked. That's why I got confused. Thank you so much.
 
Thread Starter #514

deville_56

Honoured Member
Joined
Sep 11, 2009
Messages
2,971
Likes
4,806
Location
Trivandrum
Last edited:
Thread Starter #515

deville_56

Honoured Member
Joined
Sep 11, 2009
Messages
2,971
Likes
4,806
Location
Trivandrum
October 2020 - No One's Perfect

Barricade was running smoothly after service

2020-10-20 09-24-18_2.jpg


and boom, gear lever linkage fell off. Second time someone forgetting to tighten it up. Last time, they didn't put even the bolt.

2020-10-22 11-11-15_2.jpg


It'll sit back without a bolt, so was able to reach back home.

2020-10-22 11-11-35_2.jpg


Took a longer bolt from the parts bin, in case the next guy forgets to tighten in up, the bolt will take longer to fall off.

2020-10-25 17-00-43_2.jpg


Voila!

2020-10-25 17-03-51.jpg


When old school is literally too old school. They cut the Allen bolt to fit in a flat screwdriver [frustration]

2020-10-25 17-06-19.jpg
 
Thread Starter #516

deville_56

Honoured Member
Joined
Sep 11, 2009
Messages
2,971
Likes
4,806
Location
Trivandrum
November 2020 - Insurance Renewal - Switched to Acko

While checking options, Acko was quoting the lowest. Been using New India for past 10 years and thought of a change. Acko was offering paper-less renewal and virtual and complete cashless claim. Reviews were good. Already had Acko on the Polo 1.2. They gave free 1-month extension during lock down. Renewal was pretty simple. No need upload any documents or vehicle photographs. Just had to enter vehicle number, select the make and model, owner name as per RC, and obviously mobile number and email ID and check and make payment. Policy was mailed instantaneously. Got the best IDV as well, ₹ 24,425.00, while New India was offering around ₹ 15,000.00.

Third-Party Premium - ₹ 752.00
Own Damage Premium - ₹ 63.00 (after 50% NCB)
GST (18%) - ₹ 146.70

Net Premium - ₹ 961.00
 
Thread Starter #517

deville_56

Honoured Member
Joined
Sep 11, 2009
Messages
2,971
Likes
4,806
Location
Trivandrum
November 2020 - My Boy turns 11

Except the last screw ups, running strong and fine. Needs valve adjustment, since not properly set recently. I can feel one of the valves ticking.

2021-01-10 14-06-07.jpg


Fate and dream. Booked Dio, but ended buying FZ. Story in first post. Now I got both. Dio not mine, but like mine and now my daily commute. It's 18 years old and clocked between 80k and 90k km (speedometer replaced).

2020-11-07 09-42-22.jpg
 
Thread Starter #518

deville_56

Honoured Member
Joined
Sep 11, 2009
Messages
2,971
Likes
4,806
Location
Trivandrum
December 2020 - New Horn Relay

The 10-plus-year-old relay conked off in the torrential rain. It was a Mobi Tech branded one, which was the only one available then when metal ones was predominating the market. Horn kept honking, disconnected the fuse.

IMG-20201128-WA0020.jpg


Water seeped in causing rusting. Used to open and seal the relays installed outside with rubber based adhesive, but forgot with this particular one, but still it survived good 10 years.

2020-12-10 14-52-37.jpg
2020-12-10 14-52-42.jpg
2020-12-10 14-54-01.jpg


Bought new Roots relay.

2021-02-28 17-13-21.JPG


Sealed one.

2021-02-28 17-13-26.JPG


Had to drill the clamp to accommodate bigger bolt. Usually these are just screwed on to body.

2021-02-28 17-13-35.JPG


Clamp is removable to fit inside relay box.

2021-02-28 17-13-44.JPG


Added sleeve to minimize exposure.

2021-02-28 17-16-09.JPG


Cleaned and applied petroleum gel inside the connector.

2021-02-28 17-18-22.JPG


Plugged in.

2021-02-28 17-18-55.JPG


Installed and to be forgotten for another 10 years [evil]


2021-02-28 17-21-02.JPG


Threw away the air filter rubber shroud (again). It's annoyingly hindering removing the air filter box cover.

2020-11-27 17-56-26.jpg
 
Thread Starter #519

deville_56

Honoured Member
Joined
Sep 11, 2009
Messages
2,971
Likes
4,806
Location
Trivandrum
February 2021 - Fixing Fuel Gauge + Misc Jobs

Most of the FZ owners (and also others with digital fuel gauge) face this annoying problem of low fuel always blinking. Usually gets fixed after cleaning the connectors, but when the fuel float is not detected by the meter, it starts blinking full tank, which is super frustrating than the former.

2021-02-28 17-36-08.jpg


The connector sits right under the tank.

2015-05-27 09-59-15.jpg
2015-05-27 09-59-32.jpg


Removed the clips from the plastic outer socket and wires were broken, as expected.

2021-02-28 17-31-37.jpg


Brand-new clips.

2021-02-28 17-34-46.jpg


Crimped.

2021-02-28 17-40-33.jpg


Connected and problem solved

2021-02-28 17-41-30.jpg


Rubber grommet well nut holding the tank panels on to the chassis. Only one each side, rest 4 per side being spring nuts. Damaged over time, but no one bothers to replace them. Bolt was also missing.

2021-02-28 17-22-18.jpg


Had Pulsar ones handy. These costs ₹ 14.50 a piece, but the star screw coming along with these costs only ₹ 4.00. These are for visor for all Bajaj bikes. Yamaha charges almost ₹ 60 for a bolt and ₹ 80 for a nut spring, no clue of these grommets.

2021-02-28 17-22-27.jpg


Fits perfect.

2021-02-28 17-24-20.jpg


Had perfect bolt in bin and grommet compresses well.

2021-02-28 17-24-58.jpg


Had another type in the parts bin, forgot which one.

2021-02-28 17-26-57.jpg


New plug and play connector for 12V socket. Old one had thicker gauge wire, which was an overkill. Connectors were corroded and damaged over time. Most mechanics didn't bother to connect back the ground.

2021-02-28 18-09-35.jpg


Routed.

2021-02-28 18-13-28.jpg


Grounded directly to battery this time. Positive via fuse.

2021-02-28 18-23-51.jpg


Connected to the Xenos Stingray socket.

2021-02-28 18-24-30.jpg


Another problem noted after head work is oil depletion. No smoke, no oil in filter box. Took almost half liter top up in 1.5k km. 200 ml may be from complete drain from last engine rework.

2021-02-28 18-43-10.jpg
 

Attachments

Thread Starter #520

deville_56

Honoured Member
Joined
Sep 11, 2009
Messages
2,971
Likes
4,806
Location
Trivandrum
February 2021 - Annoying Brake Pad Rattle

Brake pads were rattling even on slightest unevenness of road and more annoying over potholes and unpaved surfaces. Same happened in 2017, ended in caliper overhauling. Thought of resetting pads and greasing at first.

Pads were in great shape 35k km of use. No noise. Visually good for another 5k km. These were from FZ version 2. Cleaned them with degreaser aka Vim liquid and sanded them perpendicular to their plane of wear.

2021-02-28 19-06-25.jpg


Caliper pin replaced in 2017. No bad.

2021-02-28 19-08-47.jpg


Greased the pin with TVS-Girling caliper grease.

2021-02-28 19-08-17.jpg
2021-02-28 19-08-21.jpg


Installed back.

2021-02-28 19-22-08.jpg


Initial run was fine, rattling has reduced, but still present.
 
Thread Starter #522

deville_56

Honoured Member
Joined
Sep 11, 2009
Messages
2,971
Likes
4,806
Location
Trivandrum
Does shimming help ? Have heard that over the time shim sheets get between the sleeve and pin and again cause noise, but can last upto 3-6months in my opinion(If calliper pin wear is ok)
Shimming works on cars, but not on bikes as the pins are too small to accommodate the sheets, but are easily replaceable.
 
Thread Starter #523

deville_56

Honoured Member
Joined
Sep 11, 2009
Messages
2,971
Likes
4,806
Location
Trivandrum
March 2021 - Caliper Repair (Again)

One of the main causes of rattling pads was faulty return spring. Got these back in 2017 from India Spares, but the site got hacked and never came back. I was skeptical about finding them at spare counters as many of the child parts were depleting from their stock and never restocked. Luckily found them at Muthoot Yamaha.

Return Spring - 5US-F5977-00 - ₹ 26.00

2021-03-12 17-16-38.jpg
2021-03-12 17-16-51.jpg


Old return spring. The damage caused by disc rotor and imprint they caused on the piston can be seen here.

2021-03-12 17-26-02.jpg


Insulator and dust seal seems swollen.

2021-03-12 17-26-07.jpg
2021-03-12 17-26-14.jpg


Pushed back pistons and cleaned the caliper.

2021-03-12 17-29-21.jpg


Caliper Dust Cover - 5US-W0053-00 - ₹ 18.00
Caliper Insulator - 5US-W0068-00 - ₹ 22.00
Had both in my parts bin.

2021-03-12 17-30-42.jpg
2021-03-12 17-31-41.jpg


Insulator. Swollen vs new.

2021-03-12 17-32-11.jpg


Dust cover. Swollen vs new.

2021-03-12 17-32-13.jpg


One of the guide pins is rusted. Both pins and removable but not available as child part.

2021-03-12 17-33-31.jpg


Sanded and cleaned. Gotta buy brake cleaner next time.

2021-03-12 17-33-44.jpg


Old caliper return spring and pads. Itched to replace pads as well. Lot more life left, but feels hard.

2021-03-12 17-38-03.jpg


Caliper grease.

2021-03-12 17-38-33.jpg


New return spring installed.

2021-03-12 17-40-25.jpg


Trial fit.

2021-03-12 17-41-09.jpg
2021-03-12 17-41-28.jpg
2021-03-12 17-47-47.jpg
2021-03-12 17-47-55.jpg


Installed.

2021-03-12 17-45-49_1.jpg


Caliper pin.

2021-03-12 17-52-36.jpg


Greased and installed.

2021-03-12 17-55-19.jpg


Caliper ready for install.

2021-03-12 17-56-58.jpg


Ready to roll.

2021-03-12 18-09-16.jpg


Found another one.

2021-03-12 17-14-37.jpg
 
Thread Starter #524

deville_56

Honoured Member
Joined
Sep 11, 2009
Messages
2,971
Likes
4,806
Location
Trivandrum
March 2021 - Oil Change

Castrol Power 1 Cruise 15W50. Bought during last year's lockdown relaxation. One litre used then had to be drained prematurely due to unprecedented gearbox rework due to the shoddy job of the previous guy. Pretty sure, this litre also won't be utilized fully due to extreme low usage.

2021-03-14 18-09-37.jpg


Drained and filled.

2021-03-14 18-15-01.jpg


Drain plug and crush washer. Still brand new.

2021-03-14 18-38-48.jpg
 
Thread Starter #525

deville_56

Honoured Member
Joined
Sep 11, 2009
Messages
2,971
Likes
4,806
Location
Trivandrum
March 2021 - Brake Pads

I was sceptical about changing pads as they had enough life left, but it was hard and noisy and causing play frequently, may be due to oval'd hole. This time, got the original version one's pad, which they don't stock usually. Surprisingly, Yamaha updated their packing, now similar to the Japanese packing. Bought from Spark Automobiles, the neighbourhood store.

Brake Pad Set - 5US-W0045-00 - ₹ 152.00

2021-03-22 15-12-21.jpg
2021-03-22 15-12-46.jpg


Bybre make. Same pads shared with Pulsar 220, non-ABS NS, RS, etc., but ironically costlier than Yamaha.

2021-03-22 15-13-01.jpg
2021-03-22 15-13-12.jpg


Got to push the piston all the way in for new pads.

2021-03-23 10-29-34.jpg


Screwdriver and mallet and it goes in. High time for a C-clamp.

2021-03-23 10-35-56.jpg


Pistons all the way in.

2021-03-23 10-36-20.jpg
2021-03-23 10-41-13.jpg


Old vs new. Version 1 vs Version 2.

2021-03-23 10-36-44.jpg
2021-03-23 10-37-08.jpg
2021-03-23 10-37-46.jpg


Just curious to use the vernier caliper sitting idle in cupboard [lol] Difference is about 2 mm.

2021-03-23 10-39-50.jpg
2021-03-23 10-40-05.jpg


Greased the pins.

2021-03-23 10-43-05.jpg


Installed.

2021-03-23 10-51-15.jpg

2021-03-23 10-51-19.jpg
 

Top Bottom