Yamaha FZ16 with 250cc engine swap

Lavs · 20th October 2010, 15:40

Another Mod FZ you might be interested:

Specs - 250cc, 4 Valve, DOHC, Water Cooled, 6 Gear, 25ps, 21.5Nm.

All done with my own hands. All systems, switches, indicators, interlocks functional in the bike.

Presently working on 6 Gear indicator display, Engine temperature and battery voltage display.

aargee · 20th October 2010, 16:40

@Lavs - Yes its sure interesting & my respects to you for building with your own hands

You didn't rebore the cylinder to 250CC which I'm sure; how did you manage the 250cc & 4 valve engine? And it doesn't look like Ninja either. And how did you measure the hp? Appreciate to shed some details. Tks.

Lavs · 20th October 2010, 17:11

Imported a brand new engine from abroad. Bought a new FZ16. Took out the stock engine and replaced. Took me six months to do it. Still a lot has to be done. Power specs are directly from the manufacturer.

aargee · 20th October 2010, 17:15

Quote:

Originally Posted by Lavs

Imported a brand new engine from abroad.

Whatever it is, still its one hell of engineering to be done & I can vouch it wouldn't be a direct fit. Good work there mate.

Stock engine of which one? Fazer 250? And I hope the tech specs are at the crankshaft & not at wheels right?

PS - I somehow feel you're not willing to disclose much of info or is it just my feeling?

Lavs · 20th October 2010, 17:44

@aargee - Replaced stock 150cc FZ16 engine with the new engine imported from China. Yes it was not at all a direct fit, infact the new engine has asymmetrical mountings protruding more on one side. Everthing had to be worked upon to fit the thing aligned with changed big rear sprocket and bigger chain. And foremost I wanted to make the thing reliable and capable of offroading for going to LEH. Took me full six months to bring to this shape. I can write pages and pages on this experience.
But I can support anyone on mechanical and electrical upgrades if someone is stuck. And ask what u want to know and I will tell you everything.

pulsarmaniac · 20th October 2010, 19:09

first of all i would like to congratulate you on the mods.

i have a few doubts though.
1. Chinese are known to deliver low quality products. AFAIK, apart from a few manufacturers like LIFAN,Jiangsu Lingyu, most of the chinese bikes are unreliable due to bad quality engine and parts. i hope your engine proves to be reliable but it wont be as sturdy as the yamaha FZ16 stock engine for sure. so although you have a bigger engine now, i doubt that it can score anywhere near to the reliability of the yamaha.
2. is it legal to use an engine which has a different engine number than the one endorsed in your RC book/smart card. anyways it will grab the attention of the cops due to the radiator and bigger block for sure. is there a legal way to endorse the new engine number in your registration?
3. how is the stability and handling of your bike after the modifications. i am sure there will be some issues due to the heavy motor.
I hope you don't mind answering my queries.

aargee · 20th October 2010, 19:39

Quote:

Originally Posted by Lavs

@aargee - Replaced stock 150cc FZ16 engine with the new engine imported from China.

If possible, pls share the details, if not, no issues.
Instead, if you can, pls shed some details as how you zeroed in on this engine or what kind of research needs to be done?

Quote:

Originally Posted by Lavs

Yes it was not at all a direct fit, infact the new engine has asymmetrical mountings protruding more on one side.

Yes, I expected this reply; so how did you manage mounting the engine? The engine would've had different mounting points & the FZ's frame would've had different mount points. So how did you match them?

Quote:

Originally Posted by Lavs

And ask what u want to know and I will tell you everything.

Thanks mate; What type of sprocks did you settle for? Did the engine come with the front sprocks or did you custom make that one too? Or did the manufacturer help you decide the sprocks or you found out from a similar motorcycle as how many T's should the sprocks contain?

Quote:

Originally Posted by pulsarmaniac

2. is it legal to use an engine which has a different engine number than the one endorsed in your RC book/smart card.

I hope that part was skipped, if I'm not wrong.

Quote:

Originally Posted by pulsarmaniac

anyways it will grab the attention of the cops due to the radiator and bigger block for sure.

Well, most cops might notice the difference, but wouldn't make out or can't imagine this type of mods probably. But when caught, has to slip without RTO's notice.

Quote:

Originally Posted by pulsarmaniac

is there a legal way to endorse the new engine number in your registration?

Well, IMO, there's no legal way I guess

Quote:

Originally Posted by pulsarmaniac

3. how is the stability and handling of your bike after the modifications. i am sure there will be some issues due to the heavy motor.

Yeah, me too have the same questions; would eagerly be expecting to hear from @Lavs

Lavs · 21st October 2010, 11:42

@argee and pulsarmaniac - The engine carries the same serial No. as the stock engine. It is possible when you buy a brand new engine from a manufacturer.

Engine Mountings: I am a simple guy, so I simplified the things and it was possible to do it. Will post pics of mountings, give me some time for it.

Sprocket: I used sprocket and chain set of Bajaj Avenger. That is 39T rear with six mounting holes. Had to modify the mounting holes. I wanted to go 44-45T rear but is not available. But using 39T gives me excellent cruising speeds and for immediate power I just need to shift down a gear. Front is 14T.

The engine weights only 34.5 Kgs, accessories extra. The weight has not increased much. I compensate as my weight is less than 70 Kgs.

Being a new engine I am not going very fast. But driving at 110kmph in sixth gear was trouble free with no stability or handling issues. But I do plan to stiffen the front suspension a little. A few hundred kms more and then I shall inform you guys of the top end.

You can try Lifan, Yingyang, Dongben etc. But most engine manufacturers are interested in bulk orders. Manipulation required.

This engine is a improved copy of Honda MD21E used on AX-1 and NX250.

somspaple · 21st October 2010, 13:37

@Llavs: a great feat there!

I think this deserves the thread of its own. and the way that you have posted it as if some cosmetic mod to the bike make people doubt was this really done

.

bike looks neat! as good as right out of factory. please lets have a separate thread along with proper details and work-flow.
congratulations!!

aargee · 21st October 2010, 14:51

Quote:

Originally Posted by Lavs

@argee and pulsarmaniac - The engine carries the same serial No. as the stock engine. It is possible when you buy a brand new engine from a manufacturer.

You mean the number on the crank case is it?

Quote:

Originally Posted by Lavs

Engine Mountings: I am a simple guy, so I simplified the things and it was possible to do it. Will post pics of mountings, give me some time for it.

Yes pls; 'cause I couldn't understand your reply or may be I wasn't clear in asking about the engine mounts on the frame.

Quote:

Originally Posted by Lavs

Sprocket: I used sprocket and chain set of Bajaj Avenger. That is 39T rear with six mounting holes. Had to modify the mounting holes. I wanted to go 44-45T rear but is not available. But using 39T gives me excellent cruising speeds and for immediate power I just need to shift down a gear. Front is 14T.

But my basic question still remains as what made you to settle on 14-39? You'd loose a considerable amount of top speed isn't it?

Quote:

Originally Posted by Lavs

A few hundred kms more and then I shall inform you guys of the top end.

Thanks

Quote:

Originally Posted by Lavs

You can try Lifan, Yingyang, Dongben etc. But most engine manufacturers are interested in bulk orders. Manipulation required.

Thanks for the info; but manipulation like what?

Quote:

Originally Posted by Lavs

This engine is a improved copy of Honda MD21E used on AX-1 and NX250.

Thanks again.

pulsarmaniac · 21st October 2010, 14:55

Quote:

Originally Posted by somspaple

@Llavs: a great feat there!

I think this deserves the thread of its own. and the way that you have posted it as if some cosmetic mod to the bike make people doubt was this really done

.

bike looks neat! as good as right out of factory. please lets have a separate thread along with proper details and work-flow.
congratulations!!

+1 to that. even i think it deserves a seperated thread. he can discuss the modifications in details and it can be useful to many members here in the future.
@Lavs:Thanks again for answering to my questions. Great job there brother!

Lavs · 21st October 2010, 15:46

Sorry but I do not know how to start a new thread - If the moderator can advise, I do not have any problems...

@ aargee - Number stamped neatly with a star before and after the number. And the bike itself is limited edition, so can be different.............
14-39 - I will gain on top speed and lose on torque. I want to change the ratios to limit top end at 135-140 and increase the torque. This was the only set readily available.
Manipulation to generate interest in the manufacturer to sell to you.

Give me another two months and and only enthusiasts will be able to differentiate it from a stock FZ. I dont want people fingering the bike when I park it somewhere, so should'nt look different.

Randhawa · 21st October 2010, 19:57

@Lavs-Click on to the drop down menu on the left at the bottom of this thread. Select Motorbikes and you will get to the motorbike section of the forum. Top left you will see New Topic under the header and press that to create a new post as you like.

Sheel · 21st October 2010, 23:16

Is it praaji with Gen-1 Accord having sooper alloy wheels?

adityasiera · 22nd October 2010, 00:19

Fantastic stuff Lavs. Hats off to your ingenuity.I am pretty sure that the stock mechanicals of the FZ can handle the extra power.
How about a Disc at the rear?
I also notice that the Exhaust is different, did you design your own exhaust for the engine ?

20th October 2010, 15:40	#1
Lavs BHPian Join Date: Sep 2009 Location: NCR Posts: 45 Thanked: 143 Times	Yamaha FZ16 with 250cc engine swap Another Mod FZ you might be interested: Specs - 250cc, 4 Valve, DOHC, Water Cooled, 6 Gear, 25ps, 21.5Nm. All done with my own hands. All systems, switches, indicators, interlocks functional in the bike. Presently working on 6 Gear indicator display, Engine temperature and battery voltage display. Attached Thumbnails
	(4) Thanks

20th October 2010, 16:40	#2
aargee Senior - BHPian Join Date: Jan 2010 Location: TSTN Posts: 6,233 Thanked: 9,616 Times	@Lavs - Yes its sure interesting & my respects to you for building with your own hands You didn't rebore the cylinder to 250CC which I'm sure; how did you manage the 250cc & 4 valve engine? And it doesn't look like Ninja either. And how did you measure the hp? Appreciate to shed some details. Tks.
	() Thanks

20th October 2010, 17:11	#3
Lavs BHPian Join Date: Sep 2009 Location: NCR Posts: 45 Thanked: 143 Times	Imported a brand new engine from abroad. Bought a new FZ16. Took out the stock engine and replaced. Took me six months to do it. Still a lot has to be done. Power specs are directly from the manufacturer.
	() Thanks

20th October 2010, 17:44	#5
Lavs BHPian Join Date: Sep 2009 Location: NCR Posts: 45 Thanked: 143 Times	@aargee - Replaced stock 150cc FZ16 engine with the new engine imported from China. Yes it was not at all a direct fit, infact the new engine has asymmetrical mountings protruding more on one side. Everthing had to be worked upon to fit the thing aligned with changed big rear sprocket and bigger chain. And foremost I wanted to make the thing reliable and capable of offroading for going to LEH. Took me full six months to bring to this shape. I can write pages and pages on this experience. But I can support anyone on mechanical and electrical upgrades if someone is stuck. And ask what u want to know and I will tell you everything.
	() Thanks

20th October 2010, 19:09	#6
pulsarmaniac BHPian Join Date: Aug 2008 Location: Bengaluru Posts: 225 Thanked: 13 Times View My Garage	first of all i would like to congratulate you on the mods. i have a few doubts though. 1. Chinese are known to deliver low quality products. AFAIK, apart from a few manufacturers like LIFAN,Jiangsu Lingyu, most of the chinese bikes are unreliable due to bad quality engine and parts. i hope your engine proves to be reliable but it wont be as sturdy as the yamaha FZ16 stock engine for sure. so although you have a bigger engine now, i doubt that it can score anywhere near to the reliability of the yamaha. 2. is it legal to use an engine which has a different engine number than the one endorsed in your RC book/smart card. anyways it will grab the attention of the cops due to the radiator and bigger block for sure. is there a legal way to endorse the new engine number in your registration? 3. how is the stability and handling of your bike after the modifications. i am sure there will be some issues due to the heavy motor. I hope you don't mind answering my queries.
	() Thanks

21st October 2010, 11:42	#8
Lavs BHPian Join Date: Sep 2009 Location: NCR Posts: 45 Thanked: 143 Times	@argee and pulsarmaniac - The engine carries the same serial No. as the stock engine. It is possible when you buy a brand new engine from a manufacturer. Engine Mountings: I am a simple guy, so I simplified the things and it was possible to do it. Will post pics of mountings, give me some time for it. Sprocket: I used sprocket and chain set of Bajaj Avenger. That is 39T rear with six mounting holes. Had to modify the mounting holes. I wanted to go 44-45T rear but is not available. But using 39T gives me excellent cruising speeds and for immediate power I just need to shift down a gear. Front is 14T. The engine weights only 34.5 Kgs, accessories extra. The weight has not increased much. I compensate as my weight is less than 70 Kgs. Being a new engine I am not going very fast. But driving at 110kmph in sixth gear was trouble free with no stability or handling issues. But I do plan to stiffen the front suspension a little. A few hundred kms more and then I shall inform you guys of the top end. You can try Lifan, Yingyang, Dongben etc. But most engine manufacturers are interested in bulk orders. Manipulation required. This engine is a improved copy of Honda MD21E used on AX-1 and NX250.
	(1) Thanks

21st October 2010, 13:37	#9
somspaple BHPian Join Date: Jan 2008 Location: Bangalore Posts: 342 Thanked: 915 Times	@Llavs: a great feat there! I think this deserves the thread of its own. and the way that you have posted it as if some cosmetic mod to the bike make people doubt was this really done . bike looks neat! as good as right out of factory. please lets have a separate thread along with proper details and work-flow. congratulations!!
	() Thanks

21st October 2010, 15:46	#12
Lavs BHPian Join Date: Sep 2009 Location: NCR Posts: 45 Thanked: 143 Times	Sorry but I do not know how to start a new thread - If the moderator can advise, I do not have any problems... @ aargee - Number stamped neatly with a star before and after the number. And the bike itself is limited edition, so can be different............. 14-39 - I will gain on top speed and lose on torque. I want to change the ratios to limit top end at 135-140 and increase the torque. This was the only set readily available. Manipulation to generate interest in the manufacturer to sell to you. Give me another two months and and only enthusiasts will be able to differentiate it from a stock FZ. I dont want people fingering the bike when I park it somewhere, so should'nt look different.
	() Thanks

21st October 2010, 19:57	#13
Randhawa Senior - BHPian Join Date: Oct 2007 Location: Brighton Posts: 1,192 Thanked: 355 Times	@Lavs-Click on to the drop down menu on the left at the bottom of this thread. Select Motorbikes and you will get to the motorbike section of the forum. Top left you will see New Topic under the header and press that to create a new post as you like.
	() Thanks

21st October 2010, 23:16	#14
Sheel Team-BHP Support Join Date: Jul 2006 Location: Purnea (Bihar) Posts: 9,580 Thanked: 14,396 Times View My Garage	Is it praaji with Gen-1 Accord having sooper alloy wheels?
	() Thanks

22nd October 2010, 00:19	#15
adityasiera BHPian Join Date: Aug 2008 Location: 127.0.0.1 Posts: 324 Thanked: 432 Times	Fantastic stuff Lavs. Hats off to your ingenuity.I am pretty sure that the stock mechanicals of the FZ can handle the extra power. How about a Disc at the rear? I also notice that the Exhaust is different, did you design your own exhaust for the engine ?
	() Thanks