Hello Tech Gurus !!

I am new to xbhp and have been reading every single post on this thread. I own a 2010 fazer btw.
I cant help but have my mouth open wide in awe of the mods you people talk about and the amount of knowledge patiently posted on here.
Hats Off to the contributions from everyone, more importantly Lucky Luke and Mad Mik . Now a layman like me understands the true potential a conventional 150cc block has !!

Cheers

Welcome to this little dark corner of Xbhp.
Thank you for the kind words but there are others out there with more knowledge than me (I'm still learning about bikes, Much used to powering up turbo Jap cars)
I hope you hang around and feel free to ask questions.

Yeah Joel is very helpful when things go wrong but it's very difficult to get him. My big-bore kit with stock exhaust and too rich main jet is giving me lot of headaches but I can't explain the way I'm enjoying the power deliverance. Especially from 0-85 km/hr. Even p220s won't come near me in that range. My point of view is Joel needs to take time to do his homework well so that people like me who are very far won't get in trouble wasting time and money. I think I have spent almost 5k on the re-work done. Changing the position of carb slide, faulty bore kit, adding paper gaskets, etc, etc.

As Abhimnayu says it's all part of the game at the profit of mindblowing pickup!

Once you get your FFE you will need to retune your carb. This is why (in my opinion) its best to do the power up in 1 hit. That way you only need to tune it 1 time, Instead of multiple tunes and having to ride with tunes more suitable for the next stage power up.
I'm sure that (with your rich AF) installing a FFE will help clear up the over rich tune.

I also know you had some problems with your cylinder. I guess as RC gets more publicity and more people are buying Joels products and posting/advertising about them, there will bound to be some problems with it, Its just a matter of time with the amount of kits out there.
Having said that the onus is still on the final installer to measure and verify that the parts are within spec.

You don't hear about every single "Good" kit/install out there BUT you tend to hear about every "BAD" one.

Oil cooler on FZ-16 (Fazer)

Hi all,

Since many of us live in very hot parts of the world, and we al know that the FZ-16 engine (specially in it's "Boosted", Big bore etc...versions (!!!) tends to get pretty hot)) you will be interested in the installation of an oil cooler for this bike.

It starts by modifying the filter cover, plugging the communication between the center and the peripheral oil conduits, and welding pieces on the filter cover to connect the "banjos" for the oil pipes. No need to say that this has to be done carefully, NOT a DIY at all!



The two oil pipes (here actually brake fluid hoses....hope they will stand the oil temperature: brakes can get VERY hot, but not during that long time!) are then connected and directed behind the "Y.R.C.S." spark plug cooling scoop (there is still ample space there for cooling it), paying attention to protect the hoses where they touch anything, and are far away enough from the exhaust, right where it comes out of the cylinder head: very hot there!:



The hoses are then connected with their "banjos" to the radiator that has been installed below the fairing, in front of the engine cooling scoops and grill, far enough from the front wheel mudguard even at maximum suspension stroke, and supported using two of the horn supports (two horns on a Fazer - don't know how it is on the FZ-16 and -S). You will notice that a last minute bit of grinding or the cooler's frame was needed to keep the fork's gyration angle (to be finished and painted later):





The radiator (or cooler) is well in the air flow right below the front fairing, without disturbing the flow to the cylinder head.
I still have to experiment this installation, regarding the hoses particularly, but another person who had done the same installation (on a 250 Yamaha trail bike) and had an oil temperature meter fitted confirmed a 20 deg. C. temperature drop.

While this was being done at my usual mechanic, the starter clutch was also changed, as well as the "R.C." camshaft installed, together with new rockers, bearings, etc... Valves are perfectly gas tight, so I did not have them "disturbed". The difference in power with this new camshaft is very perceivable, without any flat spot at all as some have reported, nor any special "noise" but that of a bit more valve gap than before (to be re-adjusted once all these new parts will have mated together). Better a fraction too much than not enough!

I have high revved either, yet, and will do an objective test of the new camshaft gain going up my "usual" bridge, and testing max speed....later!

That is one heck of a mod!! One query though.. does your 200CC build require so much cooling coz the 180cc RC build doesn't. My suspicion regarding the so called cam noise is also on the rockers and other essential head parts not being replaced when the new cam was installed. Though i would be able to confirm the same only after mine is done.

One more thing i wanted to add.. Apparently the Fazer's alternator's peak output is 125-130 watts whereas FZ's peak output is 100 watts. This was told to me by the seller of the HID kit. Though i cannot confirm on the same, probably Mik with his volt meter can tinker around and give a perspective in this regard.


Cheers,

Maybe not on Mumbai, with temperature regulated by the seaside, but we have 38 to 40 C. here! Also, this is not only something I have noted on my bike (that it gets hot!), but have read reported by many, right here. So, with an (apparently: but I have nobody to compare to) much more powerful and essentially more torquey engine than the RC 180 cc. kit, to have extra cooling simply makes sense.

Wrong, definitely!
The alternator (official Yamaha workshop manual for ALL FZ-16) delivers 125W. under 14V. @ 5,000 rpm, and the regulator has a rated voltage of 13.7/ 14.7 V. and rectifier capacity of 20 A.

Acceleration on 420m.

I found this picture which shows a bridge where I start at zero speed right at the road color change and reach 120kmh right before the top, which is after 420m. , measured on Google Earth. Before fitting the RC camshaft, the speed at the top was 115kmh.
Max height of the bridge (above high tide) is 47 meters. Considering that I start higher than even high tide water, this means about 10% slope.



This to show that it is really worth doing some "mods" on this FZ16 (mine is a heavier Fazer, plus my 80kg of beer filled belly!), and that the RC camshaft gives a substantial power gain (thanks Joel!). I remember how painful - and not even always possible - it was to just reach that speed when my bike was stock!!! I do not yet know what is the max speed (on the odo) fully crouched since I have not found a bit of flat road with little enough traffic (and no cops!) to try it. Sitting up is an easy to reach 125kmh.

As a "reminder" to those who did not follow (bad pupils!), the mods on my bike are the following, in no special order:
- Rear disc brake
- "Midnight Special" color scheme ad stickers (does not change the speed much )
- 205cc. capacity with Honda (?) 250cc. piston
- 2mm. larger diameter Kawahara race valves, as recommended by Joel Joseph, with three angles, and seats (also three angles) machined accordingly
- Combustion chamber re-worked for compression ratio 10.5 : 1 (= 19.5 cc)
- Intake and exhaust porting with 2mm. increased diameter (80% at the throat)
- 2mm. larger diameter intake manifold and connection rubber
- 29mm. Mikuni CV carburetor
- K&N air filter in lieu of the stock one
- Arrow muffler on specially designed S.S. header pipe (calculation by Joel Joseph)
- NGK Iridium spark plug
- Programmable (9 maps) CDI, without rev. limiter
- Race Concepts (RC) camshaft
- RC "race" clutch springs plus one extra steel plate
- 15 teeth front sprocket
- 2 x HID projectors with angel eyes and LED "eyebrows"
- Oil cooler

I was always told racing stickers adds hp when sitting on the center stand

Adds even more hp when sitting on the bar stools!

Hey Guys.

Is there need to change oil pump when doing oil cooler modification on FZ just like Lucky Luke?
Luke can you give some good inputs ? Does the oil pump can push the oil to the cooler or there
will be a need for upgraded oil pump.?

Thanks and hope for your enlightenment.

REgards!

Hi,

May I, please, suggest you to delete the [IMG] texts when you reply to a post that contains pictures. There is effectively no need to increase the download time by endlessly showing the same pictures. Just your question suffices.
Now, answering to your question:
- First, the oil is no more pushed "up" than pulled "down" in an upward loop. The weight of the liquid wanting to "fall down" equals the weight of the liquid one wants to "push up". What increases the pressure is the extra friction, and the various "venturis" (restrictions). That is little and there is no need to touch the oil pump.
- Second: why would you want to install an oil cooler like that on a FZ? Do you have a RC "Big Bore"" kit, or other, or are you super-hot-rodding your bike to the point it will need extra cooling? In Joel Joseph 's setup, where he has a cast alloy cylinder block around the steel sleeve, there is perfect contact between both and no need for extra cooler. In other cases, where a new sleeve has been pushed in the alloy block (that you can call cylinder too...), the contact may be not as good and the cooling affected. On top of that, if you go for even bigger than RC Concepts BB kit, like in my case 205cc, and this in a very hot country (Vietnam is as hot as the hottest places on India), it is just a good thing to do. Otherwise: loss of time and money, extra risk of leaks and of damages to the vulnerable elements (cooler and flexible pipes), etc...

Hello Guys!

@ Luke. Bro Thanks for very informative idea regarding my query. Sorry for the photo attachment, Im a new forumer here who wants to know more bout our bike. Im just wondering about the oil cooler since you guys already had modify it. Once again thanks for the answering. Have a goof day. Godbless

Just planning to modify my black/green Fz-s so needed some help.........i wanna know where can i find led side logo for fz-s,i have seen a black side logo with white led in that ....and second i wanna add a body part to my bike ...the green part in the stunner pic below the engine .... i have circled it in red....I live in kandivali (Mumbai) ...so can u guts suggest me will i be able to add that stunner part on my bike ??R the color of fz-s and the green stunner matching??or any other alternative simlar to this part will be appreciated and where i can buy those led side markers except the original ones??
..THANK YOU

Review of Raceconcepts Free Flow Exhaust (FFE) on Yamaha FZ-S:



My identity card:

Simple one line--A biker by passion, but a frustrated software engineer by profession-- I am Chandan from Bhubaneswar.

Does the word "Yamaha" need a description ?

Guys, please allow me few lines to describe what I feel about Yamaha.

No one in this earth can complaint about the performance of Yamaha bikes..rather I must say, when we think about the term "bike", the first picture comes to our mind is Yamaha, rest all may be summarized under a more formal term "2-wheelers".

Oooh-huh !! Well, well, well...

I may be overflowing, but the world knows what Yamaha stands for and they have proved it again and again. They have given some ever-remarkable 2-wheeled 2-stroke monsters to Indians, starting from the Cheetah like RX 100, the stylish 5-speed RX-Z 135cc to the ever-best RD 350 ()in US they call it "Rapid Death"). And perhaps everyone here (including Indian cricket team captain MS Dhoni) knows what a RD is. No explanations please ! Owning any of these bike now-a-days, will etch you the fame of a not-less-than-celebrity, trust me !!

But still (not sure why) they were definitely struggling in Indian market for their existence, in the herd of so-called desi Hero Honda Splendors and Bajaj Pulsars. At that time, they only had few four-stroke bikes like Crux/R, YBX, YD125, which never tackled with so-called "KITNA DETI HAI" type Indians.

BAAAANGGGGGG !!!!!!

And then came the BIG day, way back in the year 2008. For Yamaha India as well for extremely over-populated and economical Indians. History was re-written !!
Yamaha showcased it's best, when it introduced Yamaha R15 and FZ16 to Indian crowd. And it changed Yamaha's fate (also massively affected all other 150 cc segment sales).


Why this Kolaveri Kolaveri di ? (If I am praising Yamaha, then what is the need for a modification)?

After riding my Yamaha FZ-S for more than 3 years, I became bored of its power/acceleration. And also now-a-days, the roads are flooded with FZ16/FZ-S/Fazers. So to be very honest, it is not a head turner anymore, just like we have more Pulsars on Indian road than the population of Switzerland :P
So, I thought of making something special which will serve two purposes i.e, performance and looks/showcase. Performance means power delivery/acceleration for my ride and looks means attracting more heads towards my bike...I may be overflowing but ...yes could not resist from revealing the truth.

(The bike asked me) So what do you want from me, my dear rider ?

Hmmm...my dear machine, gimme more..I want more, sky is the limit.

I need a better throttle response as well as a litre-class Vroom Vroom sound. Okay, my dear rider...let's see. I know you love me more than the girls, so I should return your loyalty


What did I do initially to get boosted up ?

 And for that pick-up thing I installed a K&N flatbed type free flow air filter model YA 1611..got it through a friend staying in US. Confirmed from the sole distributor for India that it yet to come to India (at that time). Believe me, perhaps, K&N is as much discussed among bikers as Biryani is experimented among foodies !! What I mean here is, everyone who is passionate about bikes, knows what a K&N is (forget its merits/demerits which is again a different chapter altogether, I am only saying about its popularity/craziness).

YA1611 was especially and exclusively designed for FZ 153 cc which sits directly in the stock air-box, no alteration, no pipes, no cleaning required. Even no up-jetting of the carburetor is needed as confirmed from Joel. Just plug-n-play.

I got a little better throttle response and a very little change in the sound. Rather the universal conical type filters increase the sound a bit more. But yes, it is the engine sound, not the exhaust sound. And most of all will agree that engine sound is not good for this small 153 cc mill.

 Also I installed a NGK Iridium Spark plug and a Splitfire twin core spark plug connector cable. Some say, it increases initial acceleration, some say it decreases the low-end knocking sound in top gears, some say it burns the fuel efficiently by providing more spark and thus increases the mileage. Trust me boys, don't know what exactly I got from this combination. But yes, my model do not have a kick starter and I have never failed to start my bike on the first touch of my thumb even on winter mornings..

 For getting little bigger sound, I made the outer opening of the exhaust a bit wider (replaced the old small pipe with a wider pipe by welding). But I ended up with some flat spots (low and frustrating response from engine) and a bit bigger phat phat type sound.

 Finally, not satisfied with what I got till now.


OMG !! What to do now ?

I researched a lot and found many aftermarket exhausts like:

 KRP (Kaulson racing Products) FFE
 Raceconcepts FFE (our own master Joel's masterpiece)
 LeoVince (costs 12000 INR, used in racing, Italia brand and value for money, but extra loud)
 Yoshimura (very good, but costs a bomb in my pocket)
 Akrapovic (very good, but tears my pocket as well)
 Daytona Dagrex (Yamaha authentic, costly but performance not up to that extent , as reviewers said)
 few others in the market


Come on man..decide:

Finally after a big big confusion, I shortlisted LeoVince and RC FFE. But I took a bet on RC FFE after talking to Joel. And yes, Italians (LeoVince is an Italian brand) have nothing left to prove in terms of design and engineering, everyone knows it... Let's see what our Desi guys make


I got my dream piece of metal:

After I placed the order, I had few sleepless nights, trust me. Extremely eager to see it and try it. Finally, It came to me via a well-packed courier. Within no time I took it to my friendly mechanic and he fitted it with no time. Totally 3 mechanics were engaged in fitting this pipe, only due to their craziness (they left all other bikes and revolved around my bike curiously). And FYI, I removed the DB killer from the beginning.


The result:

Jet-set-go !! My mechanic said me, "Boss, I am done with the fitting. Pls start ur bike..."

Ignition turned ON, engine kill switch ON, thumb on the self starter button...Pause~~~

WOWWWWWWWWWW !! This was the first word came from my mouth. I had a big relief in my face..EUREKAA...HURRAY....I got it...I got what I wanted...but yes, just the sound...it was idling on neutral. I revved it and the whole crowd stared at my bike and also at me :P.

I took her for a spin and amazed...is everything okay ? Kya baat hai bhai....OMG...the response was awesome. There was abundant torque everywhere, literally everywhere, throughout the RPM band. The initial pick-up was awesome, a never before experience. The sound was blasting without the DB killer.

With DB killer:

The power starts after 5000 RPM. I installed/removed it several times...finally removed it. Sound is brisk, bassy..somehow similar to a RTR's sound (even I liked it, though not the most).

Without DB killer:

Hurray!! The power is available right from the word "GO". The FFE performs amazingly throughout the power band, in any gear. Plenty of torque available to drag the bike. THe bike quickly reached redline and aso the 100 kmph mark.

PROS:

 Owner's pride, neighbor's envy

 Plenty of torque, though out the RPM band

 Better acceleration anytime, better 0-60kmph/90kmph

 Booming BIG sound, like the bass-filled vroom vroom of a litre- class bike :P

 Even with the DB killer ON, it sounds bassy..more than a RTR.

 Plug and play, no adjustment required

 Can smoke stock FZs in no time..they will only follow you

 114 kmph in 4th gear, which is a day dream for stock FZ (just like India winning a Football World cup! )

 Lastly, a DEFINITE head turner in small towns like mine. The bike catches attention of everyone including the never-faithful humans and the ever-faithful dogs.. :P


CONS:

 Looks, not that good. Even other cheap/ordinary after market exhausts look better.

 The making quality/dimensions. This is certainly a plug-n-play as Joel promises (hats off for that, boss); but if someone looks from behind it is not in parallel with the tire/chassis.
Looks bent outward (I think you got my point) in an awkward manner, not parallel the bike like the stock one.

 Suspects the build quality since not made up of stainless steel; that's why Joel is producing a new fully SS grade one which is having a black paint as well to make it a dual-colored.

 Finally, a cop-magnet..in big cities, definitely cops will stare at you with RED eyes, even cops are human..they are even mesmerized by its booming sound. So you need to pull the
clutch to lower the sound (near cops/traffic posts)

 Last but not the least, dogs (in Hindi "gali ke kutte") start barking at it and chase in herds...happened to me at leat 30 times in 5 months...I think the Decibel in which the sound comes out has some wonderful sync with that of a dog's bark...so they think some big creature is barking at them.


I got something miraculous/magical:

The 4th gear. Yes, you heard it right.

In this gear, you can ride at 22kmph like a snail without any knocking and also you can roar like a Spartan warrior at 115 kmph.

Once another guy who was riding a stock FZ tried to go past me on a straight highway..and thank God, I was in a challenging mood..I accepted his challenge and said "lets see brother.." and twisted my throttle...I just zoomed past him in no time..and he also was in more than 100 kmph and was thinking that I am also riding on top gear...but to his ignorance, I was on 4th @ 114 kmph...and was roaring like a liter class racing bike with BIG booming sound..he was amazed when I put 5th gear and disappeared before his eyes...

But yes, I don't do/try this on a daily basis..even riding @ 115 kmph in 4th gear will NEVER give you any pleasure !! That's why people are opting for 15T front sprcket to cruise at more than 100kmph smoothly..


What is yet to be experimented:

Try it with stock air filter. Instead of the K&N flatbed air filter, I want to test it on the stock air filter. I am damn sure the result would be different..reason: simple logic says: output depends on input, I mean the bike can throw more exhaust gases via the FFE only if it takes more air via an air filter.or else, from where will all these gases come ? nowhere..

But it is still on the experiment desk..lets see.


So, what are the final marks ? passed or failed ?

Yes..full marks to RC FFE...it is a value-for-money FFE. We have others in our hand like LeoVince, Yoshimura, Akrapovic, Daytona, KRP..etc, but this one is a real VFM item. Hats off to the master, Joel.

I would suggest anybody to go for this FFE. Even I am getting a better mileage after putting this. Approx 48 kmpl with sane riding and 42 kmpl with road scorching insane riding..

Signing off...as I said earlier, a biker by passion, but a frustrated software engineer by profession-- Chandan