No problem mate. Take your time. We are in no hurry Good things need patience and time

Joel does the big bore kit come with all the necessary parts or would we have to buy some extra parts from Yamaha before going for the build?

Thanks Abhimanyu for the price list.

@Amul, it doesnt need all the individual parts, its a complete bolt on pack. What Abhimanyu is trying to do, is to create a "as good as new" engine. So all new parts. This is not compulsory, but is a very smart thing to do.

Oh now it makes sense! Thank you satyenpoojary

That's some great modification planning........Nice write up also.

Where is the rest of the write-up Pratik? Waiting to hear

Happens with everyone! They end up enjoying the 'new' bike and slow down on the report!

i am eagerly waiting to hear the remaining story(with pics)...:-)

i am eagerly waiting for your remaining log, excellent writeup ,its very interesting to read the step by step process of mods .....

+1
Have enjoyed going through the earlier posts. Looking forward to the rest myself!

Assembling it all together to create the R16

The metamorphisms to R16

Getting it all together

Before starting any disassembly it is extremely important to make sure all the tools required to complete the project are ready and handy. Therefore, it made sense to create a checklist to make sure that all the tools and parts were available before starting the disassembly. The list of tools required looked something like this:
1. Open ended spanners of sizes 8, 10, 11, 12, 14, 16, & 22.
2. Ring spanners of sizes 6, 8, 10, 11, 12, 13, 14, 16, 18, & 22.
3. Socket set of sizes 6, 8, 10, 12, 14, 16, 18 & 20.
4. Set of screw drivers (Regular & Phillips).
5. Allen key set.
6. A set of files and emery papers of various roughnesses.
7. Impact Driver along with long Bits (Phillips & Regular).
8. Spark plug socket.
9. L shape socket lever
10. Hammer.
11. Mallet.
12. Socket wrench.
13. T Handle.
14. Nose Plier & Flat Plier.
15. A can of WD 40.
16. Valve spring compressor (must if replacing the cylinder head)(borrowed from a friend).
17. Bearing Puller (must if replacing the cylinder head)(borrowed from a friend).
18. Feeler gauge set (must if replacing the cylinder head).

I have already listed the parts and fluids that I had put together in my preceding posts.

In addition to the above, there were a few things I would have preferred to have i.e. a torque wrench, a weighing scale, compression gauge, a good vernier calipher and micrometer. I had the vernier calipher and micrometer set, but gave it away to an engineering student couple of years back. And my old torque wrench is not working. Looks like I am going to need to invest in a new set once again. Please note that while a torque wrench is not absolutely necessary, I do consider the tool as extremely useful and desirable for finishing a good build. The pair of vernier caliphers and micrometer are also not compulsory unless you are going to blue print the engine, however they would have allowed me to measure various tolerances and write a more complete build report. Which unfortunately will need to wait for the next rebuild. So now I know what I need to get on my next trip abroad.

A good workbench would also have been preferred, but since I did not have one, it was improvised with an old auto rickshaw tyre (if holds the engine perfectly) and a small footstool.

As I have mentioned before, I did not have any experience with 4 strokes and the place where I had most anticipated I would have problems was with the assembly of the head components. Therefore, I asked a couple of friends who are very experienced with 4 stroke engines to assist me when I start the work. I had also informed Joel that I would call on him if I required his inputs.

So finally after planning and plotting for almost 10 months, the D-day had come. It was fittingly on 2nd of January. I was giving myself a new year’s present.

The disassemblyNext... the Assembly

I am loving every words.

will not get better than this , detailed writeup i am loving it.......

Awesome write up mate. Really descriptive and inspiring. Loved it.

@abhimanyu31:- Great post buddy. I am hooked, please continue....