Yeah man,get it set right at a heat press shop.Otherwise even a cold hydraulic press is better than banging it with a hammer.
Yeah bro bought one on sunday and getting it done at Satish's garage.

No need to tamper with the crank or anything That's why i took up this modification.I asked ZEN and fiero has the oil cooler provision designed into it by suzuki.That's why the engine and design is being praised so much by others.It's a seriously well engineered design.
Now,if you look at the fiero/RTR's crank case/clutch cover area,you will notice that the oil lines are external.That is the pump is pumping the oil up to the head and the gear box too.The gear box gets a second line with cooled oil as well.So that, it was designed keeping in mind a oil-cooler addition in the future.
So all it needs is connecting the oil cooler hoses in place of the existing pipes.
No ,thanks, bro

Hahhha yeah,coming to the oil pressure,it is important and from what mech is saying we will know once we connect it and check it.His reckoning is that pumping pressure is enough and the oil cooler will be mounted just like on p200.
Today is a holiday for the mech and he has some personal prob,so yesterday nothing much got done.Hopefully tomorrow he will get the metal pipe of the third hose which showers oil to the cogs.Then new hoses will be made to suit the fiero and then we will have to check the oil pressure.If pressure is found lacking,we will not install the oil cooler.

@All

I got this idea from RockrzHe had done a oil cooler mod to his hunk and i asked ZEN about it after reading his post.So it's not my original idea.

@All

Correction big time!!! Mr Murthy was busy the last few days so i had asked a mech there about this oil cooler provision!! Just a few minutes ago i contacted Mr Murthy and guess what? There's a bolt in the crank case and all it needs a connection to the hoses of the oil cooler!!! That's it!!! so the existing oil lines stay the same!!That's why they had been saying it was built into the engine/gb design!!! Thank god nothing was done till now!!

Yeah Thank god the present oil lines were not modified...After seeing the earlier post I was about to make a request to you not to insert the cooler in the outer oil lines,since it is for supplying oil to critical areas,....and loosing pressure ,and circulation time will lead to definite engine problem..
Take one step at a time and take the time needed,and get it done perfectly....as you usually do.
Best of Good Luck

A good idea gixxer, even i was wondering that if the existing lines are tampered, it will be difficult to actually get a constant flow (in or out) of the radiator thingy, and still keep up with lubricating the other parts, still not leaking oil (as my bike does).

Besides, i really don't think that this might help noticeably.

@ PSR.

Any more details about the mechanism of oil cooler actually working ?
The one used by bajaj guys that is...

@gixxer_junkie_m, psr: Mileage found as 40kmpl.
Why has it gone down so much? It used to give 43-45kmpl consistently earlier.
Can we attribute this to worn out clutch plates&camchain?
Idling is perfect.
Shall I take a pic of the sparkplug for your reference?

Worn clutch plates is one possibility...also remember over a period of time dust accumulates on the Air Filter making it restrictive and makes the AFR richer.
A pic of Spark Plug will definitely help.

Like Gixxer said ,if there is provision for attaching the oil cooler in fiero then it will greatly help....The oil pump inside will be able to generate the pressure to circulate the oil through the cooler
Two things that must be observed,......one is that the oil Quantity to fill up the oil cooler, and two the time taken for filling it again when doing a start from rest of say 1 or 2 hours...I guess a non return valve is necessary to ensure that the oil in cooler does not bleed back into sump....
More indepth study is essential before embarking on this,to ensure that ,neither the circulation pressure, nor the quantum of oil in circulation through different galleys,suffer due to the mod.

Ok, I was myself thinking of getting the air filter changed-it has been pretty long.
As for clutch plates, they were changed for the 1st time at 35K kms., next at 44K kms.&now the bike is at 57K kms. I have not seen the mech. changing it all of these times.
Any idea why the original plates lasted this long&the subsequent ones are not lasting more than 10-12K kms.?
There is no metal clutch plate available for Fiero F2 unlike Suzuki Fiero.
I will also post a pic of the plug over the weekend. Please PM me your email id.

Fiero belongs to the old school when OE parts were superior to replacement,unlike now.Try to get the Metal clutch plates which will last longer due to it's ability to withstand heat and it will not bend under pressure on load.

Yes, all these things have to be kept in mind.Firstly, the quantity the oil-cooler holds and secondly how many kicks does it take to fill the oil cooler up.Then i think we have to check after idling it that the oil level is OK and do changes if needed.
A P200 manual info about the oil-cooler capacity would be helpful.

Yeah i am going to the ZEN mech this time,Rajesh that is.Let's see.
Yeah buddy,it'd have been a bit of a mess if i had gotten it done.Let's see,for the moment i have no idea where that provision is and it will be clear once i meet Mr Murthy.
Benefits of a oil cooler?It won't be felt like other changes made.But i believe that it's addition will help the engine longevity and on high revs.
There are quite a few things which are not in order,take one thing at a time otherwise you won't know which is causing which.

here is an explanation of how decompression in bikes work...

How an auto decompression cam works - YouTube

Wow, that was a new thing to learn.
However i doubt that the centrifugal force was enough to keep it exactly opened.
I sure know it does, but still it difficult to convince myself.

Besides PSR sir, I've send you an e-mail, have a look.