As for the compression and fuel. Its normal to keep the compression under control if you have bad fuel. Nothing to worry, since you have already lowered yours. We get decent fuel in Bangalore. Not sure of cochin.
Finish the run-in fully and start opening it in.

THE SILENT KILLER FZ-18 -- LOOKS STOCK BUT WILL VROOM LIKE A ROCKET


Before I bought Yamaha FZ-16, I was in a impression about it's bully attitude. I thought this one would take over every one. Maybe because I didn't get the chance to ride bigger bikes, I was in a false imagination. After buying the new vehicle, I was still in impression that there was something better in it than others. After two months, I had chance to do a touring involving big bikes like Duke 200 and the old Pulsar 200s and we had great time exchanging our bikes and riding and when I rode Duke 200, I really felt FZ-16 lacked power comparatively.

I had two options - either to buy the better bike or modify the existing one. Buying better bike would have been better choice but the mileage was an headache for me. I wanted some bike which would give atleast 45 and my fz-16 was just hovering around 37-38 km/l. I was very disappointed. Then came in my mind to do the modds and when I searched race concepts website, I was impressed the tag "Increase in mileage by God margin". I atleast took two months searching all over google.com to know about the reliability of joelled fz-16 and I found out very few failures and didn't also witness many success stories. I was in complete dilemma whether to go for modds or not especially when I saw the story of big bore kit of R-15. I called Joel few no. of times and Shivang (Shv18) was the one who explained each and everything about the big-bore and he was also reason to take this step of getting the bike modded˙.

Finally on 19th October Friday 2012, my bike was joelled and it was a very adventurous attempt because my friend stays at one end and joel's workshop stays to the other end and in between there is big confusing bangalore city and getting to each side is like crossing a sea!


19th morning when I reached Joel's workshop at 10.30 a.m., I couldn't see any board of race conecpts because he had just shifted and still the interiors being done. Joel came in a maruti omni and was surprised by his hospitality, he didn't talk much but slowly we got together as time passed by.

I was wondering how these people bash this poor chap, can't blame him, he is there alone to answer everyone. Hope he would create more Dummy Joels so that he can solve our problems.


Pre Modd Suggestions:

It's better you modd the new bike in good condition or else you will end up bashing Joel for no reason. Those who have finished 25k plus on ODO need to open up the engine and check out all the bearings and crankshaft and need to replace the same. Ask your mechanic about the condition about the other parts before you setup this BB kit. Since the tolerance of piston is very high, you need the other parts in very good condition. The whole engine overhaul would be good for the old bikes no matter if you wanna spend extra 10k.

The Modds:

Big bore kit (cylinder, piston and rings)
High Lift Camshaft
Racing Clutch Springs
Simota Performance Air filter
29mm CV Carburettor
Stock Head Porting (Joel's signature work and his secret)


The Crew:

Two of Joel's mechanic came and they were asked to do the big-bore on my bike and they were told to start the work after I get back because I was to go and get the money from an atm. After getting the money the work began. These guys were so expert that they started dismantling the head and cylinder within minutes. These guys were so good that when I would ask each questions, they would answer me. I was doing both photo shoot and video shoot. When I asked about taking the photos and videos, Joel was first reluctant and after understanding my nature, he agreed and I also understood that he wanted to keep the porting part in secret, so I didn't bother about what he was doing. Actually I didn't know what the porting was, I was thinking that the whole structure of head would be changed with some other parts and I only understood when Joel explained me about it.

Ok, Now let me explain what happened on 19th Friday.

Disclaimer: The following experience is completely my own understanding and it may conflict with the tuner's explanation and also xbhp member experts here. Any corrections and suggestions by fellow members are most welcome and I am also not to be blamed if anyone is encouraged by this experience and mess their bikes by doing the modds.



Parts Inolved:

1. Big bore Kit (piston, piston pin, rings, Cylinder)

[ATTACH=CONFIG]84175[/ATTACH][ATTACH=CONFIG]84176[/ATTACH][ATTACH=CONFIG]84177[/ATTACH][ATTACH=CONFIG]84178[/ATTACH][ATTACH=CONFIG]84179[/ATTACH][ATTACH=CONFIG]84181[/ATTACH][ATTACH=CONFIG]84182[/ATTACH][ATTACH=CONFIG]84183[/ATTACH]



2. High Lift Camshaft

[ATTACH=CONFIG]84020[/ATTACH][ATTACH=CONFIG]84021[/ATTACH][ATTACH=CONFIG]84022[/ATTACH][ATTACH=CONFIG]84023[/ATTACH][ATTACH=CONFIG]84024[/ATTACH][ATTACH=CONFIG]84025[/ATTACH]


3. Racing Clutch Springs

[ATTACH=CONFIG]84026[/ATTACH]

4. Simota Performance Air Filter (Stock replacement)

[ATTACH=CONFIG]84027[/ATTACH]

5. 29mm CV Carburettor

Didn't take the pics (Will post it later)



The build:

Joel's mechanics are very fast. I took just 10 mins to rip my bike. Like a rocket speed. Another Fz-16 fella came and I was worried, how they can manage both bikes in just one day and I found that that guy came only for big bore kit and not porting and no carburettor changing. They done his bike in just flat one hour and he left. The mechanic dismantled my bike in no time and I started asking about the condition of each part and he said they're in excellent condition. I thanked God when people made fun of my run-in tricks, I was alone to explain myself but now I'm satisfied that my run-in method was nearly to perfection.

[ATTACH=CONFIG]84029[/ATTACH]

These guys are very careful when installing the cylinder and pistons. As shiv said piston tolerance are very tight and the mechanic had to move the piston inside the cylinder with hand for 10-15 min to make it easy. And when installing, if he finds bit wrong, he does the work again and it's only worth to do this kinda work from there itself. This guy, building race bikes has good experience in this kind of work - a slight mistake he finds, he takes the whole thing back and build again. I thank myself that I knew a bit of kannada because he knew tamil and I knew malayalam but since he was staying there he knew kannada well and I knew bit of kannada and we managed our conversation with half mixing malayalam in it but he understood my queries.

My bike was finished by 6.30 p.m. and could see the whole work done and I video-graphed certain parts of the bike and knew many things. Going there was a blessing for me. I was more happy to see the work done than modding my bike.

Another thing noticed is that what our local mechanics take day or two to finish the work, for them is just minutes. Simple clutch plates changing, they do it just by bending the bike and without draining the engine oil. Tak Tak within minutes. I haven't seen this kinda fast work anywhere else.

[ATTACH=CONFIG]84030[/ATTACH][ATTACH=CONFIG]84031[/ATTACH]

Now the bike is built, I will give the pros and cons

Pros:

1. There is bump in power. I did 300 odd kms run-in and didn't take the bike above 4-4.5k rpm. I feel more power than stock.

2. The bike is smoother than before. In stock condition, I felt something is holding the bike but now it's freeeeee

3. Mileage has increased. At stock I would get 36-38km/l in city riding and now I get 43-45 km/l (Bangalore City Traffic)


Cons:

1. High lift Camshaft sound: There is a krr sound which I would hear very little in stock bike after 5k rpm and here the sound starts when the bike is started. Love it or hate it, this sweet sound won't subside, you need to live with it. (Joel told me that there will be decrease in the sound as the kms clock)

2. TPS won't work. New bikes have dual throttle cable fitted to the carb and a TPS sensor. The engine warning lamp will blink because TPS sensor can't be fitted to this new carb and I still doubt if there is some connection with bike not cranking.

3. Bike doesn't start with self start button. For first 200 kms bike didn't start with start switch and I had to kick. This problem was there in stock bike for the first 250 kms and once in a bluemoon after that but here I have this problem everyday. if the engine stops in traffic then it will never start with self. Those who don't have kick start will have heavy time and for them the advice is to change the battery with higher power.



The problem:


After reaching cochin, my bike started knocking and I was worried greatly. I asked Joel what would be the problem, then it was 87 Octane petrol here. In Bangalore it was 90 Octane, so there was no knocking. I also thought that the slight knocking was part of the run-in process. Joel felt sick just after getting my bike ready and he couldn't check it again. The remedy by joel was to put two cylinder gaskets in place of one so that compression can be lowered. And luckily I got a mechanic who knew Joel very well and he was very keen to do the work. Now the knocking has gone and another trouble came. The starting trouble. This bike won't start second time, I mean after the bike has run for few kms and if it stops then it won't start with self and you must give good kicks to it. Tried to call Joel but came to know he is with fever. The mechanic here suggested that change in spark plug will do the trick and I gave 500 plus bucks and changed to NGK Iridium spark plug and now the bike starts with self but still i need to give few cranks. Will do another few kms of running and find out the exact issue.


Recommendation:


I won't recommend this mod to any one unless the are ready to take the risks. If it's a beginner, then it's absolutely no. No matter if you pay for petrol still stock will be better if it comes in perfect condition. Those who live in Bangalore or near to Joel then it's a heaven for them but those stay very far need to find a good mechanic. The BB kit is risky though it's worth.

• CDI is stock

• FFE is stock

More updates to come.

Want to keep the run-in period till 2k kms.

Expected Riding style:

0-500 kms 3.5-4k RPM (slightly moving upto 4.5 once in while)

501-1000 kms 4.5-5k RPM (slightly moving upto 5.5 once in a while)

1001-1500 kms 4.5k-6k RPM

1501-2000 kms 5k RPm - 7k RPm

2001 and above, the festival of ripping will begin. Will give the top speed (FFE is stock and CDI is also stock)


Cheers

THE SILENT KILLER FZ-18 -- LOOKS STOCK BUT WILL VROOM LIKE A ROCKET

• CDI is stock

• FFE is stock

Hi mate,

Congrats on your big bore mod.
Rule the streets with The Lord

BTW why still no FFE n Custom CDI??
Any technical reasons?

I have the email reply from one of them somewhere, Indian oil claim they only serve 91 Ron everywhere, we're supposed to be on 91 Ron everywhere as per the BS3 & 4 norms

If you go to any petrol pump and ask to see the latest delivery ticket for petrol, you will see that IOC states 91 Ron for petrol and BP states err.....nada! as for HP I don't even bother

As for your CBR, the ECU will retard the timing a few degrees to compensate or else the engine will knock

Not sure what's so funny, BP and HP serve up 87 Ron petrol throughout most of the country

My good friend who works in KRL has confirmed to me that they produce 87 Ron and supply to all bunks. So as far as my city is concerned I am right.

I have the email reply from one of them somewhere, Indian oil claim they only serve 91 Ron everywhere, we're supposed to be on 91 Ron everywhere as per the BS3 & 4 norms

Then add the adulteration which is everywhere, then what you got?

Hahahaha, you know marketing tactics. Most of the things shown in Ads are not real

and you don't have to be an expert to know these silly things

and also my friend is working as doctor there and not in production dept.

confirmed to me that they produce 87 Ron and supply to all bunks

Can't rebut silly statements but will give you the updates

1. Carb tweak done, the slide was lifted up so that there is more flow of fuel. Didn't find any difference but Joel says then engine understands.

2. Starting problem has vanished as Joel suggested to keep the RPM at 1.2 to 1.3k and to first open the throttle a bit and then push the self start button and the engine starts with no problems.

I think Joel is very much in love with my babe, he is answering and rectifying each problem

ODO is just 550, trying to clock 2k as early as possible so that the party might begin.

Can't rebut silly statements but will give you the updates

1. Carb tweak done, the slide was lifted up so that there is more flow of fuel. Didn't find any difference but Joel says then engine understands.This will be the needle getting the clip adjusted. The needle is tapered. The higher the position of the clip the leaner the mix. The needle will be pushed further into the jet meaning less annular volume between the needle and the ID of the jet. Less Ann volume = less fuel can come up through.

Well Joel has pretty much finished the racing season so he would be available to help you and others out and quickly finish shipping any long overdue parts to his customers. Personally, i have always had the chance to interact and verify things before i made the purchase. If he doesn't respond on mails, i do wait knowing for a fact that being a one man show, he eventually would reply the moment he gets free from his track days.

Anyways, coming back to your ride.. i am glad that the small niggles are being sorted out. I am glad too that you have patiently and objectively tried to find the root cause of the problem and rectify it accordingly instead of jumping into conclusions.. I believe such an approach would make you love your ride and understand her more inside out.

One suggestion, check with Joel and replace the engine oil now since, you have crossed 550+ kms. If you are running mineral then shifting to a fresh bottle and a new oil filter will clean out most of the metal particles floating inside your engine. Just my thoughts.


Cheers,

Congrats on joining the "Big Boys". At last your long wait is over.
How do you feel knowing your FZ can beat pretty much all the other FZ's out there. Its a nice feeling isn't it. Welcome to the beginnings of "Hot Rodding" as you call it.

Just a couple of tips for you, It is upto you whether you do them or not.
Put your bike up on the center stand at night, Then in the morning check your oil level on your dipstick.
This will give you a more consistent oil level.

Allow your bike to warm up before riding it. Especially important with forged pistons. Give it atleast 30 seconds to allow the piston to start expansion. From my understanding, the supplied piston is a "Semi Forged" To me that means Hyperutectic Piston. A aluminium piston with added silica to make it stronger.
Hypereutectic piston - Wikipedia, the free encyclopedia



Enjoy your ride and look forward to hearing about it.

Now my question is I'm planning to change the engine oil after 1k ( ie 1280 on ODO) and want to shift to semi synthetic Motul 15w 50 but I have around half bottle of 20w40 mineral oil. So I'm thinking whether to shift to SS after 1k of current mineral in the engine or do another one bottle of mineral for 1.5k more. Today I had to top up some oil as the dip stick was showing near the minimum mark. Just confused. Can we get half litre or lesser bottles of SS oil from motul so that in case in need for top-up....

.......Yes, I will try to do exactly what you said. I'm riding sanely for first 2 kms then starting to open the throttle but the beast is eager to fly, I think it doesn't like to be controlled. Thanks for explaining me the carb tweak. This afternoon when I checked the engine oil, it was minimum and I topped it. I think I need to keep an eye on engine oil level.

I'm very much enjoying my ride. All the hard work really got paid off.

Hi,

If you want to be economical and justify the cost of half a bottle of mineral oil you have spent on, use one more round at 1k kms and then till you hit 2k kms and then replace the engine oil at 2k to SS or FS oil. Or else, replace the engine oil with SS or FS and keep this mineral oil for future periodic maintenance of the Free Flow Air Filter as mentioned on FZ18 thread.

If you do want to try out FS i would recommend Motul300V 15W 50: this brilliant oil retains its integrity even at very high revs and speeds and keeps the engine lubricated regardless of how much thrashing you do.

Your camouflaged beast's top speed test post 2k run-in is something every silent reader here on xbhp and outside would want to know about. Although bear in mind, the Speedo will have 5-10% error in readings when you do hit the top end. In a way it would be a good thing for the readers and other Noobs too; Mine would be 90% souped up with FFE and all the works whereas you ride has all the things minus the FFE. the 0-100kmph and the time taken to hit top whack will give the Noobs an idea about how a minute change in the addition or subtraction of 1 kit affects the overall performance of our respective rides.

I am pretty confident the hot roding bug now slowly budding in you will eventually make you end up purchasing the FFE and other pending kits too!! I started with an FFE upgrade and now look where i am today!!

Joel needs to be banned for making addictive substances for power hungry enthusiasts!!

If you have finished editing the video clips you shot while the build was going on, do post it on youtube and share the links with us folks.

Cheers,

Updates:

ODO is 850 kms and I had few issues of running rich when the carburettor slide was lifted up. Mileage dropped from 45km/l to 32 km/l. Told Joel about this and he asked me to check the spark plug and found it was running rich. Now the carb is just tuned and again took the pics of spark plug and sent to Joel for inspection. Joel says that slide must be reverted back (lowered) to compensate the mileage issues but will take a final decision after Joel judges the current condition of the spark plug.

Though the journey till know is challenging with tuning problems, I'm enjoying my ride. Yesterday had a small drag with an Unicorn Dazzler. This guy didn't know that my babe is souped and he disappeared in my side mirrrors in no time and still I haven't crossed 7 RPM. And just imagine what would happen after the 2k line I have drawn to have her to the fullest!

One guy at the railway crossing found my engine warning lamp blinking and advising me to immediately visit the SVC and check the issue. I was bit embarrassed. Need to do something about this TPS thing.

Joel needs to be banned for making addictive substances for power hungry enthusiasts!!