GBD approved.

The Planning

Following the 4 Ps (Proper Planning will Prevent Poor Execution)Do it once, do it right

Very well written!

Congrats on deciding to upgrade your R15. It's certainly worth it. I'm enjoying my ride everyday on the bike.

Btw, Please check your PM.

I'd call it R17 rather. If YMIS labels their 153 motor on FZ to be 160 CC, then why not a 165CC to be 170cc?

Congratulations

I remember watching someone riding the modded R15 with 165 cc with speedo topping to over 142 Kmph.

I hope yours does that too.

I would surely like to test ride yours one of these days

Can you put the price up for all the parts you have sourced so far?

can we also have some pics of the parts? their installation pics?

Getting everything together

The Big Bore Kit

The first thing to arrive was the big bore kit. Upon opening the packing I was immediately impressed by what I saw. I believe in the quote . A more detailed examination of the cylinder showed that it was as well casted as any OEM part, if not better. The finish was clean with no casting flashes or burs. There were no signs of scaling or porosity. The quality of fit of the inner liner sleeve to the cylinder was flawless with an even and clean finish. The liner walls were well honed and even. It was also observed that the liner had a nice even chamfer finish at the bottom end to assist in assembly. I was also impressed by the quality of finish of the top and bottom of the cylinder. I mention this in particular as the machining and finished were so good that I suspected that I may not need to use any gasket sealant during assembly. However, this call would be dependent of the other mating surfaces, i.e the cylinder head and the engine block. As such I would only be able to take a call on the same at the time of assembly. Overall if I were to give it rating on a scale of 10, I would give it resounding 9The Big Bore Piston
Free Flow ExhaustThe Cylinder Head

By the time I received the free flow exhaust, the culminating races of the season had Joel occupied and the cylinder head was delayed by couple of weeks. I had the choice of going ahead with just the big bore kit and the free flow exhaust and doing the cylinder head at a later date. However, as my work schedules were also hectic I decided to wait for the cylinder head. Finally, it came in the last week of December and was certainly worth the wait. I am not posting a photo of the cylinder head, as it is difficult to see changes that have been made due to the same being in the inlet and exhaust tracks and require proper lighting for good photo of the same. As the valve sizes are the same as stock, taking a look at the head from the valve seat side will not show the changes. However, once you take a look at the inlet and exhaust tracks you can see the changes that have been made. The geometry of the inlet and outlet track has been subtly changed to allow improved gas flow. Once again it should be noted that while the changes may look simple, the question not just about removing material from the inlet and exhaust track. It is a matter of exactly where and how much material needs to be removed to create the correct shape and angle. It is also worth noting that the size of the inlet and outlet tracks is so narrow that making such subtle changes is not exactly easy.

Sourcing of the remaining parts

To source the remaining parts I first went to the Factory Shop in Malad, Mumbai. I was a little apprehensive about the whole thing. Something told me that I will be told that they do not have the valves or the rocker arms as these are not exactly fast moving items. Much to my surprise, I found almost all the parts that I required at the shop. The only parts that they did not have were the valve springs.

Now for the shocker, they would not sell me the Yamalube Mineral Oil and the oil filter. Upon further inquiry I was told that the management had given instructions that these items would not be sold over the counter. I was so dumbfound that I just walked out with the parts that were available before they change their mind on these too! Next, I went to Excellent Yamaha in Andheri, Mumbai, here they gave me the oil and oil filter, however, even they did not have the valve springs. So I tried Thomsun Yamaha, again with no success. I was now getting a little annoyed, I was running around like a headless chicken for 4 valve springs that could hold up the whole project till the time I could source them.

I decided to call Joel for his advice on the same. Joel assured me that I could use the old springs without any problems and the same could be replaced with stiffer springs when the new camshaft is installed. So in a way it was a blessing disguise. Stiffer valve springs got added to the things that need to be ordered from Joel. While waiting for the parts, Joel announced that the free flow air filter was now available. Thus a free flow air filter was immediately order and the same was received a day before I started the engine assembly.

The cylinder block really looks as good as stock(even better).Thats some great machining.Making parts of such quality and that to in limited quantity is quite a big thing itself.(Have understood that after spending hours in machine shop just polishing normal shaped blocks)
Even the exhaust looks good,just can you tell of what metal is it made of?
AND as Joel says if these parts cost similar to stock ones then actually these are a steal at that price.
Need to search for a R15 now.
OT:abhimanyu sir you have a PM.

Thanks bro for posting pix and a neat detailed write up.

To be very frank with you, i had read that post from JOEL for the kits for karizma and r15 and i was thinking, if only i was in joels city. Now that you have taken that step ahead of me, i am keen to know how you went about doing it, who did it? cost involved?

Even i was thinking if the silencer could be powdercoated to black? but should not chip on heating thats concern, else chrom looks different and functional .

good luck, do post one full pic of your r17

The price of all the parts so far:

1. Head Cover Gasket x 1 Rs. 184.00
2. Cylinder Head Gasket x 1 Rs. 126.00
3. Cylinder Gasket x 1 Rs. 7.79
4. Intake Valves x 2 Rs. 778.46
5. Exhaust Valves x 2 Rs. 1150.56
6. Valve Stem Seal x 4 Rs. 100.00
7. Valve Cotter x 8 Rs. 58.72
8. Valve Spring Retainer x 4 Rs. 176.24
9. Valve Spring x 4 Not Available
10. Valve Spring Seat x 4 Rs. 264.40
11. Inlet Valve Rocker x 1 Rs. 1073.45
12. Exhaust Valve Rocker x 1 Rs. 350.00
13. Exhaust Pipe Gasket x 1 Rs. 20.71
14. Break Pad Kit x 1 Rs. 390.00
15. HEL Brake Line Kit Rs. 5220.00
Total Rs. 9900.33

Awesome review. Nice to hear the way you went ahead with your build. Thanks for your words. The R15 is indeed the most mod-friendly engine on sale right now. The handling package can happily take it all.

Now this a thread,i would say worth spending time on,well documented mate.Bring it on.

Brilliant write-up! Being an R15 owner myself, this is just what I needed. I was a little apprehensive about getting the kit since I wasn't sure how exactly I would get about putting it on my bike. As others have already asked, a good write-up on how you got everything installed too would be awesome! Thanks a lot for this! This thread just became my no.1 attraction!

btw, after you get everything done, a video of the results would be like a cherry on the cake