if tappets does not have perfect clearance it does make a lot difference. people ignore this thinking like its nothing but its a very important thing. not sure if your problem will solve or not but adjust it, because its not possible to check without opening. clearance changes by 0.01 every 5000.



new video

They ASC will do what they want to do not you want them to do. They are not provided with multiple strip feeler so forget the clearance you want. they set at minimum which decrease performance, thats why need to do at home.

17k is not too much to clog the filter. fuel pump maintains pressure so that injector can spray. injector wont clog with dust instead carbon. if clog ECU will know and will increase the stroke.

I beg to differ, I had gotten my KTM RC390's injectors fully cleaned at 22K kms, there was significant small amount of micro sand that came out of the injectors entry port on the micro fiber cloth.
Even if there is fine fuel filter, there are dissolved micro dust and sand in the fuel which do manage to get through the fine fuel filter.

So yes around 20K +-2K would've accumulated quite measurable amount of blocking particles in injectors.

Thanks kiran2508 And paul.1911 for your reply, and I really appreciate it.

kiran2508 Yes, I am on my 3rd FZ25, and there's quite a story behind it. But mainly it's the itch i have for automobile, including cars. I love spending my spare time in garages, and with some fellow automobile enthusiasts.

The whole story began in July 2018, while i was searching for a used bike for my BIL. I am a die-hard fan of two wheeler, and bought my first 2 wheeler in 2002 when I was 19 and just started to earn. It was a LML Vespa Select II.
Long story short, I have bought 12 2 wheelers since I bought my first one, out of them 8 were used. That includes Pulsar 150, 180, 220, Chetak, Access 125, CBZ, RE Electra etc. The reason for buying mostly used ones are mainly my itch of fixing things, and not financial.

While I was searching for the bike for my BIL, I came across a beautifully maintained White FZ25, before that, I was even unaware that Yamaha sales a bike in 250CC segment. Just for curiosity, I took a test ride, and fell in love instantly. It was like a match made in heaven for me, the brutal acceleration, the nimble behaviour, the lightweight chassis, seems all were custom made for me. Which I was missing since 2009 when I sold Pulsar 150UG3. I bought the bike on spot. With a plan, Just to enjoy it for some days and then sale it. I was having a Suzuki Access then and that was more practical to be kept as my wife can also ride it.

I rode that FZ25 for 2 months, clocked some 2k kms, and sold it as per plan, But till then I was already got addicted to the bike and felt very much disappointed after sold the bike.

So, at that night I decided to sale the access and buy a FZ25 again, searched olx, got one, it was April 2018 model, 7300on odo, and the owner was relocating to Canada. Next day, visited the owners place, saw the bike, took a brief TD, and bought it. It was a Black Metallic X.

Rode the bike for 14 months, clocked 7500 kms. Then an itch started again, why not upgrade? Dominar 400 was in my wishlist for a long while. Put an ad on olx and the bike fetched a great deal. Sold it off..

Shortlisted a couple of Dominar, took TD, but though I liked the bike very much, I could not able to connect to its soul. Plus, considering my hight 5'6" I was not comfortable riding it in city traffic (I live in Mumbai, and Mumbaikars can understand how worst the traffic we have). And also found the turning radius is quite high and the bike is not easily chuckable in city traffic. It's a very very good highway tourer. But not a great city bike.
So with a heavy heart, dropped it from the wishlist. Next, looked for a D390, but those which are 2018 and later models were far beyond my budget, and D250s were not enticing to me.

So again, got a FZ25. In Nov 2020. Got a sweet deal, though the bike was not maintained very well. Have spent around 10k so far on this bike, that includes, changing of fork inner tube, oil seals, some body panels, full service, swing arm and bearings, Air filter, oil filter, spark plug, brake pads etc. Now the bike is in pristine condition and looks And rides just like a brand new one. However I am missing the brutal charecter of my previous two FZ25's. But pretty sure that I will be able to rectify it.

paul.1911 I like your efforts man, and totally agree about your opinion about ASC guys. I love DIY. I am more of a car guy, and maintain my cars myself. I have even rebuild an engine in one of my car, and thoroughly documented it. But thats a story for another day and in some another place, as this forum is specially focused on 2 wheelers. I watch your videos regularly, and hope you are doing great in your new assignment after leaving your job. Wish you and your newborn goodluck!

My latest one.


The predecessor's



Same angle, because I love seeing the bike from this angle😊!

Regards
SomrajSG

Hi, my cousin bought FZS25 BS6 last month and is very happy with the purchase. On Friday he took his bike for 1st servicing and took a bottle of Motul 7100 10W40 1.5L pack along with him. He just realized that the bike needs 1.45L oil with filter change whereas the mechanic poured entire 1.5L in it. So, just would like to know from you all that does an extra 50-100ML oil can cause and damage in long run?

Not much, as it's just 50ml. However, if possible, then take out the extra oil with a help of a syringe.

But I guess, your cousin bought Motul 7100 10w50, instead of 10w40. 10w40 don't come in 1.5 L bottle, but 10w50 does.

Thank you for the detailed write-up of the back story, sometimes once you get hooked to a particular bike/car. No matter what new comes, sometimes you always go back to old comfort zone.😊

Wishing you all the best and hope you'll fix all issue and make the 3rd bike ride like the other 2 bikes.

Ok thanks, I'd let him know. Like you said an extra 50ML shouldn't cause any issues....atleast hope so!

My bike is similar. From your description, it seems like improper valve clearances are the culprit although i cannot say for certain. I've done 19k kms so far. I have ridden at least 15 other FZ25s and mine is missing that oomph (or brutal character).

On my bike, the valve clearance keeps changing (becomes tighter) on its own after about 500-1000kms. I have got the head "reset" twice, but the issue persists. Both mechanics (One of them recommended by several xbhpians, i.e., Royal Motors) say they can't find any issue, but they acknowledged that something is wrong.

The bike has new oil (I've tried several in this time, Yamalube, Motul 7100, etc.), a new air filter, clean injectors/filters/throttle body, good clutch plates, new spark plug. I've used Yamalube engine cleaner as well. Air (27/32) is filled almost every weekend. The brakes are in good condition and are not sticking or anything.

I have tried some things which were suggested by experienced owners (@paul.1911, slopegatri, JyotishmanS, Kirankarunan, ashwanth.r and ashwinprakas), but nothing seemed to help. So far I have replaced the timing chain + tensioner (even they mostly weren't responsible) and the tappet adjustment screws. The head has been dismantled and assembled again twice, with the correct timing and valve clearances (tried 0.05/0.07, 0.06/0.08, 0.07/0.10 and 0.08/0.12).

Planning to either buy my friend's FZ25, or give up on bikes for sometime. For now I have almost completely lost interest in bikes.

After finally coming home after 9 months (away because of lockdown) and being able to ride the bike for late night city rides, and some office commutes, I have to say, I think I might just continue with this 2018 BS4 FZ25.

Got a nice pull, easy on the pocket, relatively maintenance free - I was thinking of upgrading to a Jawa or RE-Int or thereabouts, but I think I'm happy with this.

Current mods are:
- Installed the LED indicators from official Yamaha ASS. I must say it adds a touch of class. I'm not sure if they did a good job of it, there's some mess under the seat. I'll see if I can tidy it when I get some time from my kid.
- Osram LEDs in pilot and rear number plate lights
- Removed the tyre hugger too, because I dont ride in the rains.

Next items on my list of mods are:
- Tail Tidy (MOTOAGGRANDIZE Tail Tidy/Fender Eliminator for Yamaha Fz 25 | Color: Matte Black on Amazon, Rs. 999)
- Liqui-Moly or 7100 10w50. I was earlier thinking of sticking to spec (7100 10w40), but reading the thoughts/opinions of you folks in the last 60-80 comments makes me think 10w50 is a better option. I'm currently on 5100 10w40.
- Perhaps upgrade to Masseters, since I claimed warranty on these MRFs last year for cracks on the base near the rim.
- Upgrade to projector lamps. slopegatri Do you mind sharing your DIY and the parts list, with links if possible? We all are awaiting a DIY


I also have some questions:

1. I see Hella modules on Amazon, but the low-beam (B00SHLA4I2 SKU on Amazon) and high-beam (B00SHLA11W SKU on Amazon) modules are separate. Is there any module that would have both the beams in a single module, so I wouldnt have to mess around with cutting the module like in your pictures on an old post of yours in this thread?
2. What socket type is used on FZ? (H1, H7, etc?)
3. You said 11w is the max that the ECU provides, so I am assuming a ballast is necessary. Do you have links to good ones?

Thank you for reading.

there are only three things which directly related to performance. Compression, fuel and spark. So,
Compression: do you know your compression is accurate? this is done thru compression check tool
Fuel: How is the spark plug color? it tells a lot of things what is happening inside combustion if there is any unburnt fuel left or carbon deposits
Spark: if voltage is low then fuel will not burn completely and can have complications in high rpm. The spark color should be strong blue not red. A multimeter is used to check ohms reading of the primary and secondary coil to look for any abnormal reading. What FE are you getting?

1. The hella modules you are referring, are not compatible to stock setup.
2. The LED setup in the headlamp is customized design and LED's are integrated on a PCB which is a part of whole assembly. The socket type you are asking are for standard headlamps, hence not applicable.
3. LED's dont need a ballast / current regulator. Already ECU is controlling the current.

Gurpal, IC engines performance depends on multiple parameters, and not limited to above three. Other than the points you have mentioned, there are many more other things which controls the engine output.

some of them are.
Timing advancement.
AFR.
Internal friction of crank bearings.
Intake pressure/temperature.

These are to name a few. We already had discussed about the valve clearance, hence not mentioned.

I am guessing for this specific problem of mine and Shashank KR, the solution is somewhere hidden in either AFR adjustment or may be with cam/crank position sensor. Which can manipulate the value of timing advancer.

BTW, I am getting a good milage of 38 to 39 kmpl, in mixed city and highway riding combination.

Hope to solve this soon.

Regards
SomrajSG

Those hella modules won't fit inside fz25's headlight.

Leds need constant current, thus requires an led driver circuit ( in fz25 bs4 its inside the headlight unit ) Ecu doesn't control this. but it does control on/off functionality.


anyway i have completed my headlight projector diy. been running for past 2-3 months. will post a how to guide and parts list once i get some free time (sorry for delay).

Thank you for the information, it's useful for me to google. Maybe I can find a way to remove just the integrated PCB + LED part if possible into reflectors. Totally going out on a limb here, and probalby worth a laugh when I see this post 3 months later.

Thank you for adding to previous comments, it helps provide me more clarity (pun intended).I'll await your DIY with excitment.
Off-topic, I live in Raipur for a few months of the year. Are you in Raipur too, or Bhilai or someplace else?