Mistaken

Sorry guys that Yamaha fellow was an a****le filled with s*it in his brain

he though that my chassis number starts with ME1220P01272000001 and told me that the it will have 5 clutch plate........

but the fact is that the my chassis number starts with ME138B...... and it has only 4 clutch plates by design ......


I got to know this from "digislayer" Signature link and informed my 2 friends to open there bike and check and they told that one has 4 clutch plates and one has 5 clutch plates

I checked this from the following link:
Yamaha Parts Price List - 2010: YZF R15 Parts Catalogue

the link was created by Sannihith Kinnera


i changed the oil and oil filter also .....

in nice road i don't remember of riding more than 120 KMPH ......... the average speed would be 80 KMPH and was taking a break every 15 to 20 KM since i had my friends tooo.... i think the max RPM would be 9000 .....

i got my bike washed and got my indicator fixed and told him to change the oil filter and then change the oil and as security measure told him to keep the bolt open for at least 10 more minutes so that all the old oil can drip out.

I hope thinks will get back on track ...........

@ abhijitkn @ nv.rohanraj

Here goes my story, will write a detailed review very soon.

This is exactly the same issue I faced initially.

Stop thinking about your Engine oil level, leakages, etc etc and Ppl here try ways to blame something else when the problem lies right below your nose, Do you think you might have ended-up in such a scenario if you were on a stock setup?????

Just a day before my bike's engine seizure, The engine oil was changed with a general service. I did complete a Run-in for about 1000kms in various RPMS varying the gears upto 7K RPM. All my happiness was washed out when I to tried to test the top speed.

Lets not dig-up deep into the root cause as MANY OUT HERE WILL NOT ACCEPT WHAT I HAVE LEARNT.

I will put it straight, The 165CC Setup that you have is not exactly 165 rather 158.XXCC with all Mathematics done, take a Vernier Calipers and check it yourself. Its the VERY high compression which makes the setup Torquier and feel better then stock and its the same high compression which the other parts like Cam, Crank, Valves etc are not prepared to handle over a certain RPM.

Fixing this problem is real simple. All you got to do is leave your bike to the Service center and they will replace the below parts and charge you for the mistake that you have done. Let me try to brief you out in different scenes that I Faced.

Parts Modded,
165CC Block,
Air Filter and Joel's ECU.

Scene 1 (April 2011)

Symptoms: All seen by you currently
Cause: No Oil Supply over the bore.
Root Cause: High Compression.

Parts replaced.
1) CAM + Racker Unit
2) CAM Timer chain.
3) Head Gasket.
4) Valve Springs.
5) Clutch Plates. (3 Nos)

These are the Main ones which I remember and lots of tit bits added.

Scene 2 (May 2011)

Symptoms: Bike refused to Self start, Very low compression, loud weird tk tk tk sound from the engine note itself (Bore/Piston)

Parts replaced.
1) Replacement 165CC bore. (Piston rings busted)
2) Head Gasket.
3) Crank Connect Rod.

These are the main ones and other minor ones added.

Scene 3 (May 2011 Month end)

Symptoms: Engine Oil Leak, Lots of Vibes and gave the feeling the bike will go down any time at high RPMs.

Parts replaced.

1) Gave the 165CC bore to an Expert, He sleeved it to 170CC precisely to fit a 170CC Yamaha Forged Piston, which is used in Yamaha Boats (Runs upto 18,500RPM)
2) In/Ex Elliptical Porting done precisely to match the setup to relieve the compression.
3) Teflon coating done to Piston head and walls. (The coating done on fry Pans)
4) Hero Honda Ambition 135 Piston rings for durability as the previous ones started to break.
5) Cat Con removed from stock exhaust to relieve a bit more compression.
6) Industrial grade coolant to suffice the excess heat generated with our custom setups.

And many more little ones....

Scene 4 (June 2011)

Symptoms: Now I got a bike which is butter smooth, smoother than stock. No Engine braking while gear shifts, Then came out the evil in me for more performance.

Parts Changed,

1) Daytona Driven Sprockets.
2) Remapped Joel's ECU to a different map (I had to do outside as I missed an appointment with him in Chennai)
3) A further more to the Porting and slight height adjustment between the head and bore, by using a couple of gaskets as advised my Yamaha service.

And other small ones.

Scene 5 (June 2011 Month end)

No issues with the bike as such, but got a chance to swap my bike's old parts with a another R15 which was damaged on the outside.

The bike was completely damaged with plastics broken outside, will not even turn on.

I took the bike to Yamaha Service and Opened it to find all internals were sparkling as GOLD. Then what, except the outer crank case and 170CC bore assembly all internals were replaced and all the Porting and other tit bits were done perfectly once again with the new parts.

Rear Tire Alloy, Front forks and rear disc were also replaced.

Now I get a feeling as though I ride a Brand new bike. Did a couple of long trips to Trichy non-stop for 300kms on a constant 110-120Kph range. Casually hit a 141kph till now and Mileage about 40-42 under 5K and 35-40 Constant without mad ripping.

But only I know what all I have done in order to bring things back to Shape.

May be I have flooded this thread with unwanted info, if any feels this is inappropriate content then kindly ignore.

Thanks

omg...... i hope i a m in trouble ........

^^ You are hoping you are in trouble???


@Harishk - Though i dont appreciate flicking the parts off someone's bike thats been there due to your dad being a cop. But interesting stuff/symptoms that you came up with. Wonder what everyones response is gonna be?

@ jd666

I would better say I earned my R15 with my hard earned money and respect every other's bike in the same way. But this bike which I used to draw the parts was already sent to condemnation.

which means all the available metal parts will be removed and sold in Kgs and the left over will be crushed.Cops dont differenciate between an R15 and a old Bajaj scooter when it comes to condemnation.

Do you think its a sin to flick the parts? Still the bike has my parts which worth the same weight


And,

this is what happened to me with the Modds journey that I had the last few months and trust me if I have to be more precise, then it has to be a complete review. Honestly I dont like to write one

^^ all due respect for your hard earned money... Even i bought all my 5 bikes with my own earning. But had you spent for the parts that you replaced, that would've been a harsher influence in telling you the loss in your experiment.

Anyways.. We are not all saints here so big deal. You got your bike back in shape, thanks to a condemned bike, alright.

i think i will get is fixed as per the input that is provided by HarishK......

I just need some more time to get the things fixed up............

i will keep you guys posted about the status of my bike and how it goes ......

Please keep us posted. My Joeled bike is under observation for next 250 Kms (run-in). Hope the engine settles down and proves the worth of patience and effort.

Did you not talk with Joel regarding this? I am sure he will take take of this.

@Harish - Most of what you say dont add up. I missed this thread bigtime.
well, here is some MATH for you.
The piston is 60mm.
CC of an engine = bore x bore x pi x stroke / 4 for a single cylinder.
60 x 60 x 3.14 x 58.7 / 4 = 165cc. I wonder how you got 158cc.
use the same vernier that you are talking about and measure the piston.
And, running-in a very subjective matter even worldwide. So I'll leave the argument here. As long as you are happy, I'm glad. In the end, facts and figures will prove what is what.

dude any update??

Well, it was addressed the next day and he is now at his native I guess. All issues as such have been clearly addressed by us and none have been left hanging. I fail to understand why nothing is addressed to me directly and instead turned into a chain of email, sms and PM exchanges with other members.
Quoting that the bigbore kit is only 158cc etc is only for a reason best known to them. Its easier when things are brought to light, and not discussed in the dark.

Unfortunately, this is the usual BS from the usual MF's, this is an epidemic in India, too much education and no practical skills or knowledge, I suffer the same nonsense in my own business, it sucks bro, but in the end you have to stand tall. As they say too many chiefs and not enough Indians or too many Indians not enough Chef's. people don't respect when someone does something good in India, instead just critcise and try to find something better, mind filled with know it all's, 'my guy said this, this one done that, blah blah, grow up and stop being so ignorant' by the way China has orbited twice in the last week, how do I get a Chinese passport? seems to be the way forward, future super power? ha! if power works in reverse, then this is the way forward, Jai Hind!

Hi Joel,

Can you let us know what was the root cause & how it was fixed? Not in detail but just few words since me & other memebers are looking forward to install big bore for Fz your response will hep clear our doubts.
Thanks.

^^^ I would like to add my two cents to this whole matter if I may ! I have been receiving a number of PMs (and everyone is welcome to PM for any information). I have always tried to maintain a balanced and unbiased view and opinion (though it is difficult when one has personally worked on the engine builds themselves). I am certainly no armchair expert. I work on my own engines and I am still learning and will keep learning as long as I ride bikes.

The point of this post is to highlight something that most people tend to either forget, or want to ignore or are seemly unaware of. Hotrodding has a certain element of risk involved in it. There is no formula for measurement of that risk by which you can say it is 'x' amount of risk for 'y' amount of changes. But generally it is excepted that that the more radically you push the envelope of performance, the risk increases exponentially.

Now, the question is how do you mitigate such risk while pushing the envelope of performance? The answer is extensive R & D and testing. Ordinary, you would need to build engines and do the said R & D and testing on your own and bear the consequences (believe me there will be consequences, more on that later). The way such risk is mitigated is that someone else has already done this R & D and testing and is offering a deployable solution for your performance needs.

There is no way that 100% results are guaranteed. Hell, even production stock bikes have problems within the first few thousand kilometers. And that gentlemen, is a fact of life. What is guaranteed is that if something goes wrong then in Joel's case he will rectify it for you. That is more than I can say for parts sourced for 'A', 'B', or 'C'.

During my 2 stroke development days I have destroyed 3 perfectly good engines, had 3 major engine seizures, broken 2 connecting rods, cracked 2 heads, had 2 big end failures and destroyed 6 pistons by melting their crowns, 2 clutch failures (these are just the ones I can recall). But I did learn a lot about 2 strokes. And yes, all of this is with my own hard earned money (and I do take exception to someone saying that we are sitting here finding faults with others and misguiding people whereas his experience is the 10 commandments tablets).

The big question you need to ask yourself is this; whom do you have more faith in: someone who is an armchair expert or someone who has built National Championship wining bikes and has been named the National Tuner of the Year 2010.

This is a free country where everyone is entitled to their opinion, but this is also a free country where you have the right to make the right choice, to sift through all the armchair B.S. and make the right choice. So gentlemen, the choice is entirely yours to make!

P.S. No offense to anyone nor is this a personal attack on anyone.