Tweet
I figured I may aswell make a contribution to the forum with regards to making a 200cc FZ bike.
I had numerous problems with the build, Mostly originating from the "Plug and Play" or should it be Plug and Pray kit from Automotivesparepartsshop in Indonesia.
I spent almost US$2000 (including Paypal's fee) and paid additional 32% Import duty + 10% VAT on the 200cc kit Including a custom big valved head with cryo treated bronze valve seats, body kit, Mikuni TM28 (carb that was supposed to have been jetted to suit 200cc) Cryo treated forged piston (that turns out to be for the standard valved head) Con Rod that was not sent and its cost converted into postage, Double row engine bearings that were substituted without my knowledge with single row fiber caged bearings, BRT CDI that was not suitable for my bike and a Alloy swingarm that was faulty causing the custom chain to cut through the rubber chain guard and into the arm itself, a supposedly ported intake runner that was only opened up at the ends, the center being untouched and smaller in diameter than the ends.
The only functional part was the 200cc cylinder bore.
The big valve head was incomplete and very poorly machined. It was like someone had kicked it around the cement floor to machine it flat, The mating surfaces were dented, scratched and scored, complete with broken cooling fins, Incorrect valve guide angles and leaking untouched valve seats.
It took over 1week to repair and finish the head, Not to mention the custom parts needed to make it function.
The engine took over 1week to build.
During the engine mock ups more problems were discovered.
This was when the forged piston supplied had incorrect valve reliefs machined in it. The custom mystery cam (no data given on this cam and I was even asked to provide data on the cam back to the supplier!) was opening the valves too much and as a result hitting the valves against the piston crown.
A RRGS Forged piston was sourced, correct reliefs machined out to suit the larger diameter valves and the factory cam put back in the engine as the supplied cam was totally unsuitable for the engine. The poor machining on the cam resulted in the back of the cam having "corners" instead of being a smooth radius. Too much stress on the valve train to be of any use to me.
Engine was finally put together, A Keihin carb with a K&N cone filter was installed on to a new bored intake runner, given a rough tune to be able to ride around. Due to the strong vacuum of the engine an extra spring was installed to help close the cylindrical slide as this had been an issue on a friends bike, Giving a unwanted "cruise control" type situation where the throttle won't close!
Finer tuning followed along with removal of an additional spring to close the slide as it was not needed.
I had to wait several months before I got a CDI that was made for my version with regards to the wiring.
That has now helped smooth out the bike considerably and increased its urge to rev.
My exhaust is a custom Stainless header pipe with a carbon Yoshimura TRC Tri Oval muffler. The DB Killer is removed most the time when I ride.
Finally got a nice bike with a bit more "poke" and grunt (torque) than the stock FZ.
My friends black FZ16 (You will see on my youtube clips) with custom header pipe and Yoshi endcan cannot keep up at all. He also weighs 50kg less than me.
I had numerous problems with the build, Mostly originating from the "Plug and Play" or should it be Plug and Pray kit from Automotivesparepartsshop in Indonesia.
I spent almost US$2000 (including Paypal's fee) and paid additional 32% Import duty + 10% VAT on the 200cc kit Including a custom big valved head with cryo treated bronze valve seats, body kit, Mikuni TM28 (carb that was supposed to have been jetted to suit 200cc) Cryo treated forged piston (that turns out to be for the standard valved head) Con Rod that was not sent and its cost converted into postage, Double row engine bearings that were substituted without my knowledge with single row fiber caged bearings, BRT CDI that was not suitable for my bike and a Alloy swingarm that was faulty causing the custom chain to cut through the rubber chain guard and into the arm itself, a supposedly ported intake runner that was only opened up at the ends, the center being untouched and smaller in diameter than the ends.
The only functional part was the 200cc cylinder bore.
The big valve head was incomplete and very poorly machined. It was like someone had kicked it around the cement floor to machine it flat, The mating surfaces were dented, scratched and scored, complete with broken cooling fins, Incorrect valve guide angles and leaking untouched valve seats.
It took over 1week to repair and finish the head, Not to mention the custom parts needed to make it function.
The engine took over 1week to build.
During the engine mock ups more problems were discovered.
This was when the forged piston supplied had incorrect valve reliefs machined in it. The custom mystery cam (no data given on this cam and I was even asked to provide data on the cam back to the supplier!) was opening the valves too much and as a result hitting the valves against the piston crown.
A RRGS Forged piston was sourced, correct reliefs machined out to suit the larger diameter valves and the factory cam put back in the engine as the supplied cam was totally unsuitable for the engine. The poor machining on the cam resulted in the back of the cam having "corners" instead of being a smooth radius. Too much stress on the valve train to be of any use to me.
Engine was finally put together, A Keihin carb with a K&N cone filter was installed on to a new bored intake runner, given a rough tune to be able to ride around. Due to the strong vacuum of the engine an extra spring was installed to help close the cylindrical slide as this had been an issue on a friends bike, Giving a unwanted "cruise control" type situation where the throttle won't close!
Finer tuning followed along with removal of an additional spring to close the slide as it was not needed.
I had to wait several months before I got a CDI that was made for my version with regards to the wiring.
That has now helped smooth out the bike considerably and increased its urge to rev.
My exhaust is a custom Stainless header pipe with a carbon Yoshimura TRC Tri Oval muffler. The DB Killer is removed most the time when I ride.
Finally got a nice bike with a bit more "poke" and grunt (torque) than the stock FZ.
My friends black FZ16 (You will see on my youtube clips) with custom header pipe and Yoshi endcan cannot keep up at all. He also weighs 50kg less than me.
You could have easily upgraded to a bigger machine, which would have been more powerful & far more reliable than your current set up. 
Comment