I don't know, Junior, and think anyway that their number is irrelevant if considering just that. What matters is the volume these baffles determine inside the muffler, how the gases "vibrate" inside these volumes, and how they get in/ out. Very complex and nobody will be able to tell you exactly what happens inside them, but the engineers that designed it, using highly sophisticated computational fluid dynamics programs!

I am Ivan from Philippines . i have already done some mods with my FZ16 PG1
and im interested with the CAM you installed on Rylan Lobo FZ16.

I want to order 1 . , by the what is the lift and the duration of the CAM you are offering ?.

So Far this are the mods i have done on my FZ
Hi Guys ,

I am New from this forum and i came from the Philippines .
I share the same interest with you guys , and i am learning a lot from this Forum Thread .
Just like you i have also Done some modifications on my FZ16 to customize it according to my liking and riding style .

I would like to share the current mods on my bike and i am hoping to get some more inputs from you guys .
Let me Know if i have done something bad on my bike and im am open for suggestions .

So Here it is , below are the Mods Done on my Bike .

A. Brakes
A.1 Front Disc Brakes
--->(Stock Rotor disc to 290mm Rotor Disc )
---> (Stock brake hose to Braided hose )
A.2 Rear Brakes
---> ( Drum brakes to Nissin Disc Brakes with Single piston Caliper)

B. Engine , Clutch , Sprocket ( 199cc )
B.1. Dynamic Balanced Cranks Assy
B.2. Faito Racing Crank Bearings
B.3. Bore Kit 66mm ( from Automotive -indonesia )

B.4. Ceramic Coated 66mm Piston top , Dry Film Laminate coating on 66mm Piston skirts

B.5. Ceramic Coated Cylinder Head ( including intake and exhaust valve face )

B.6. Ceramic Coated Exhaust port

B.7. 3 Face Angle valve seats on both stock intake and exhaust valves , leak free tested
B.8. Stock Bs26 carb Tuned jettings ( PJ -17.5 , MJ - 120 )
B.9. Free Flow exhaust , locally made
B.10 . 15 teeth engine sprocket / 40 rear sprocket
B.11. Stiffer Clucth Springs

C. Miscellanous , Looks
C.1. Stock Headlight to FZ150i aftermarket Headlight
C.2. Acerbis Handguards
C.3. Pazzaz , 2 inch Riser Handlebar
C.4. Belly Pan

Overall Appearance

So far that's it for now ...... Hoping to get your suggestions or any inputs

Hi Abhimanyu, Mik, Luke & Shv18, It would be great if you can advice me on my query.

"Will the quality of material used for wrapping the muffler affect performance? From what I understand it is used for absorbing sound. I will be refilling my FFE this weekend. The original glasswool has burnt completely. Any suggestion in this regards?"

Hello ChinMayakar ,

I my Personal experience , the Fiberglass wool has no ill effect to Engine Performance but it does to sound absorbtion .
The More FiberGlass Wool and more Compacted inside the Muffler the sound is absortion is greater so you will have less noisy exhaust system .
But overtime it will degrade , lets say 6 mos to a year and you will notice the exhaust note has become noisier , this tells you for another repacking .

So advice is tell your Muffler repair guy to put more glass wool inside and have it compacted ......





"Will the quality of material used for wrapping the muffler affect performance? From what I understand it is used for absorbing sound. I will be refilling my FFE this weekend. The original glasswool has burnt completely. Any suggestion in this regards?"[/QUOTE]

Hi, Welcome to the forum, Nice work on your bike. Just hope that Hary's engine will hold together.
Did you get your brakes (front and rear) from J2Cab in Manila?
The rear disc set looks like the same one that I got with a Honda caliper sub assembly, Sonic rear disc and a machined sonic? hub. I wish I got a black caliper instead of the red but anyway I'll take it over the drum anyday.
I had met the owner of J2Cab (his name escapes my mind) in my hotel lobby in H20 Hotel Manila Bay, He was kind enough to deliver in person my rear disc kit, and answer a few questions and also discuss our "friend" Hary.... J2Cab had told me he bought some of Hary's "kits" and had to complete them (same as Luc and myself) Also the big brake upgrade had the wrong bracket to mount the caliper, So J2Cab had to make his own.

I like the ceramic coating and the teflon skirts, I had asked Hary about these when I was inquiring about the parts but told me it was not available. Where did you get these done? If you did it locally will you also get your exhaust header pipe treated? (if it isn't already done so) Keeping the heat inside the pipe = hp. We used to do the same to our turbo exhaust manifolds, exhaust compressor housing and dump pipes. The ceramic coating was that effective you can briefly "touch" the surface of the pipe.

How many km's have you covered so far?
Did you or your mechanic who installed it come into any problems?

The glasswool serves a dual purpose, Not only absorb the sound but insulate the muffler skin from heat. Fiberglass is as we all know a great insulator.
Get a very dense matting if you can, The matting on the Yoshi is dense (it was a little wet though) Just be careful when handling the fibers. Protect your airways, skin and eyes. Nothing worse than itching hours after you have been handling it.

excerpt taken from wikipedia
Glass wool - Wikipedia, the free encyclopedia

Uses

Glass wool is a thermal insulation that consists of intertwined and flexible glass fibers, which causes it to "package" air, resulting in a low density that can be varied through compression and binder content. It can be a loose fill material, blown into attics, or, together with an active binder sprayed on the underside of structures, sheets and panels that can be used to insulate flat surfaces such as cavity wall insulation, ceiling tiles, curtain walls as well as ducting. It is also used to insulate piping and for soundproofing.

Hi Mik ,

Thanks for the warm welcome ,

Please find my answer to your question :

1. J2Cab owner is Alex Cabrera ( actually i got the 66mm bore kit from Him but he ordered it from Hary )
My front brake is from malaysia , FZ150i aftermarket part
2. The Ceramic Coating was done by Precision Engineering from Manila ( A special shop building racing car machines , for BMW and Merc )
3. I did not do the header pipe yet since , i still thinking of a better one , plus it is too pricey givent the size and area that will be threated
4. How many km's have you covered so far? , ---> I have already did 4000 plus km since we installed the kit ( mostly running a min of 230km per trip ) long ride with extreme elevation and straights , so far no issues with it , Fuel consumption is 33~35km/l
5. Did you or your mechanic who installed it come into any problems? So far its a plug and play for our case after i had it processed at Precision Engg .
But before that i had the bore Honed at Precision Engg and the Piston ceramic coated and Dry film Laminated on its skirts

The issue i had during this build was the Crank bearings , since it had the crank assym , dynamically balanced during the process the Crank bearings went bad .... so after 1000km break in period we had to rebuild the engine again and this time i replaced the crank bearings , with a racing spec bearing which is the same as LC135 .

So far i havent touch the head and Carb department of the engine and i feel that is good enough for me for reliability .....
The gains i have with this current mod is already good enough , i dont want to do the big valve stuff since it will be raising the power band at hi RPM but flat at Low RPM .
My Riding style demands power and Torque at low to Mid RPM and i am not interested with Top speed .

Comment about the Hary's Kit ---> SO far the kit is not perfect the bore is conical on the top area the Lower part is slightly tighter than spec but the upper part is tigh ---> Normally they intentionally do it on their Racing Engines on their part of the world , but since i use the bike for touring i have it Honed at precision engg to spec ..with the crisscross honing pattern ( Hary's bore comes with a smooth finish )

hey,is the stock exhaust muffler also packed with glass wool?
yesterday i saw a bajaj discover 100 with custom clipon handlebars.i enquired about them from the owner and they are available in the city for rs2000 approx.also these clip ons will not change the riding position.the only benefit i found was they looked better than the stock 'bicycle handle' and made the bike look more sporty.are there any pros and cons of getting them installed apart from asthetics?

Luc had the same conical bore on his cylinder. He had to get it repaired.
If you got a streetside mechanic to install your engine I'm sure you will have run into problems. What was supposed to be a 2 day build turned into over 2 weeks!!

Anyone interested in a FZ with a 300cc and 4 Valve head?

On a more interesting note.

I was hanging out at my mates shop (mechanic who does my bikes) and I noticed a engine getting built.
It had my old 153cc cylinder sandwiched between the gearbox case and a knife edged port and polished 4 Valve head (and nice cam too).
To say I was excited would have been a understatement. Yes it was just a cylinder substitution with engine case and matching head.

I'm aware that there are sets of aftermarket cylinder kits that are available in sizes up to a volume of 300cc for a certain bike, Favoured by the illegal racers around here.
The only modifications needed are (and he has done these before on his personal bikes and customers) moving the 2 bolt holes on the chain tensioner side of the cylinder. The 4 holes that go through around the piston, align with the engine case. No need for these holes to be touched.


What does this mean?
There is a possibility of making a 250, 260, 270 cc and even up to 300cc engine, Simply by swapping the Yamaha Factory cylinder bore and the 2V head with the aftermarket cylinder bore, Piston and head kits. These kits I've seen and handled in his shop are of fantastic quality. They are not a factory cast item, These are custom cast, machined and finished for racing applications.
Currently its a matter of getting your existing cylinder, bore it out or resleeve it and hone then find a piston suitable (Though it should be find a piston first, then bore your cylinder to suit) and get your gasket machined to a bigger ID (Internal Diameter) to suit the new bore.

The amount of "catalogue" parts supporting these upgraded cylinder kits is amazing. You want a different cam? pick one from the catalogue that meets your needs, You want to modify your valve train? n problem. Look up what you want, then place a order, A flow tested cyl head that has been Port and Polished from the factory with 3 angle valve jobs? No problem.
No more having to do so much custom work on the FZ engine when its already been done on another engine.


Imagine a 4V 300cc FZ winding out to 10K RPM on the highway
Better engine breathing, more torque, hp, More OOOMMPPHH.
Everything that the bike is lacking with the asthmatic engine Yamaha put in originally.


Will the internals be able to handle the 100% extra stresses on them?
That remains to be seen, We had a discussion about how it can work, what may break, will there be enough oil etc etc.
But for now there is a possibility of getting a "off the shelf" cylinder set, simple little mod for the 2 holes and upgrading your 153cc into a 250cc+
Of course this needs to be developed and tested should it go ahead.

Hi Mik , Guys ,

Thats another Mad idea .....
Have you guys ever think of modifying the Gearing area ?

I have seen guys at Malaysia , converting their FZ150i a 5 gear Motorcycle to a six gear Motorcycle
Their Bottom Engine share the same base with YZF R15 and LC135, so they just buy R15 parts and replace their stock gearing and its plug and play Heres the Link
---> http://www.facebook.com/photo.php?fb...type=1&theater
This is also possible with Indonesia FZ16 or Byson , they share the same base with LC135

For our case the Engine base is designed from India FZ16 . so its not possible to get the R15 gearing .
Did anybody tried this in India ? ( sixth gear conversion )

I think this is the missing part for our modded FZ16 a 6 speed gearing .....since we already have the added power .

I often keep trying to change up to 6th.
I'm currently running a 15t and stock 40t
I have a option of trying out a rear 45t.
My reasons for going larger were so I can use the alloy swingarm with greater chain to arm clearance, so it won't cut the arm. However for that arm to be re-used I need to weld a stub so the rear caliper bracket can align with it + make new spacers etc.
If I can get a different gear set I still may not go for it.
90% of my riding is in the city, Only a few runs along the 1 nice smooth road in Saigon, The rest of the time I'm doing 60kph, fighting to get past people doing 30-40kph and the occasional ride to Vung Tau for a overnight or 2 night trip.

In Vietnam, getting any parts for our FZ's is almost a nightmare.
There are only a few specialist shops that bring in parts for the FZ.
A Yamaha oil filter costs $5.50
Rear drum brakes cost around $15.

Hi Mik ,

I have already Tried 15 /44 combination , it has developed lots of torque but with slightly reduced Top speed . ( Good for Stunt )
While 15/42 combi is roughly the same response as stock ( 14/40 )
So i just opted to used 15/40 , you get better cruising speed and easier to accelerate due to a compensated Engine ..this also helps
improve FE since your Engine is very relaxed on Cruising speed at 90 ~100 ( 6000rpm at 5th gear )

By the way what drives you to use the new swing arm ? what is benefitted from it ( is it lighter ?Longer ?Beauty ?)

Hi Guys,

I wonder even with such modifications none of the owners have been able to surpass 136 kmph. I know the time taken to reach that speed has reduced. But still we all need that top end. at least a 140 Kmph.
Wonder if that can be breached. Can any one help? Coz i am thinkin of getting a Bigbore & a 29carb from RaceConcepts.

Btw i already have a Leo Vince Exhaust and a Flat K&N Filter. Would the LV FFE support the 180 BigBore.

Mad Mik, Lucky Luke & Joel Joseph & other seniors if could help.

Regards,
Rohan

The arm was slightly longer and much more lighter than the factory arm.
Needed a longer chain and also a chain with a removable link. (None of this was ever mentioned to me as it was sold to me as "Plug and Play"

Some of my US$2000 of "junk" bought from Hary's shop. I also had to pay a significant % in customs import duty.
The chain cut through the rubber chain guard and into the alloy. Everyday I had to clean the chain, sprockets, rear numberplate, under the mudflap where little bits of rubber were getting chewed up and flicked out. When I told Hary about it he wanted to sell me larger sprockets to life the chain up off the arm..... Great customer service this guy
I know both Luc and myself have been over 130kph, I have been to 135kph while "playing" cat and mouse type games with my friend with a FZ16 (Just a stainless Yoshimura muffler and custom header for mods) no tucking, Just tee shirt, jeans, FFhelmet and gloves.
Still got room to go for more top speed, Even with a 100kg rider.
Running a 15t engine sprocket and stock 40t rear.
Your LV FFE will be fine, I'm sure you can top 140kph with the appropriate gearing.

I have reached 135 on the odo. That was with a slight tail wind but also with the db killer on the muffler, and 15 teeth front sprocket.
Joel has reached that speed too (odo), with his 180cc. BB. kit , stock CDI, and 14 teeth.
I think that with new my CDI, race cam from RC, it should reach 140 kmh.

I shall describe (= continue the saga) of my mods later as I am in France right now, and busy, but with my present piston and a slightly reduced compression ratio, the bike is a dream to ride: revs up in 5th. from 1,500 rpm without a problem (well: I am usually a bit higher up ) while still revving up past redline like a race bike! Don't know about max speed yet as I am still running in (again!!!). The top speed I reach just before the top of a medium steep bridge after about 200 meters (?) is 115kmh= 5 kmh higher than before (Mik: Thu Thiem bridge starting from Nguyen Huu Canh. Can you try?). I can feel the bike pushing very well!

Are you sure of that???? These two engines look very much the same from the outside, while different from the LC 135/ 150 FI (which is NOT at all a FZ16)?