Modified Bikes

BIKE India Editor and his brother team up to design an exhaust system to juice up the FZ

The Yamaha FZ 16/FZ-S is one amazing street fighter. It has a low end grunt which every enthusiast loves in the urban scenario. Flicking the bike around the city chaos and getting the torque from the engine with a slight wring of the right wrist makes it the perfect urban tool. But then, the bike lacks a bit in the higher revs. A biker is not going to be riding in the city all the time. He will sneak out on weekends and do some highway runs. It goes without saying that he will also head towards the mountain roads where the FZ will do uphill climbs around the bends of the ghat sections. This is where the bike suffers a bit. It is strong enough till 5000 revs but after that it becomes a bit tough for the bike to match the expectations of an aficionado.

To solve this very issue and make the biker happy anywhere and everywhere he travels, BIKE India Editor Aspi Bhathena and his brother Sheri Bhathena sat down to design a free flow exhaust system. After tackling quite a few things, a completely new exhaust system was made which included the bend pipe as well as the end canister. The front bend pipe has been given a proper tuned length. The end can, unlike a regular free flow exhaust, has a specific degree and a newly calculated diameter and volume. This has resulted in a uniquely customized system that, as we expected, performs much better than the stock one.

It definitely impressed me once I rode the bike up and down the Dehu Road stretch. Pinning the throttle, the rev counter showed the needle going all the way past the redline and that too pretty freely. The engine didn’t feel stressed at any time throughout the rev range. In fact once past 5000rpm, unlike the stock FZ, the bike with the custom exhaust revs more happily. With the least amount of hesitation, the bike revs more in each gear giving a better top speed in every gear and this finally reflects in the top speed of the bike. To gauge the difference in the performance of the new exhaust and the stock one, we carried the stock exhaust along as well. Testing the same FZ with two different exhaust systems back-to-back left us with baffling results. The data recorded by our testing equipment showed that the stock bike managed 0-60km/h in 6.5 seconds where as the one with the free flow exhaust crossed the same mark in merely 5.2 seconds. (The figures of the stock bike are different from the one we tested earlier since this was a used bike and tested in a different environment than the one that we rode during our road test).

Even the top speed of the FZ has gone up considerably from 110km/h (true) to 114.7 km/h (true). While delivering the performance, the sound level has also been kept as low as possible for the free flow exhaust. Though it is louder than the stock one, it is not at all annoying for the rider, the pillion or the people around them on the road and in the neighbourhood. Apart from the performance gain achieved on the FZ, another modification has been done to the bike giving it a better braking ability. The rear disc break unit from the Pulsar 220 has been installed on the bike to improve the overall braking at higher speeds.

For further details and to buy one of these for your very own FZ, contact: Prakash Kunthe +91 9822442911 Sheri Bhathena +91 9850057477 Pramod +91 9422080811

Mulund lad, Gaurav custom builds an exhaust system for the YZF-R15.Adhish Alawani finds out if it performs better

Yamaha introduced the YZF-R15 with the intention of acquainting Indian bikers with hardcore performance. No doubt, the Japanese company successfully defined track performance with the R15 in India. However, most costumers in the country are going to use the bike in cities and for sport touring on highways. Like a trademark Yamaha race bike, the R15 has its power band in the higher revs, more precisely over 7500rpm. Riding the bike in such high revs is not practical on a daily basis in town. The R15 definitely feels a lot sluggish from the bottom end to the midrange making it a chore for tackling traffic.

Gaurav, an avid BIKE India reader and a hardcore sports touring fan, decided to modify his R15 so that it would deliver a better midrange performance. To start the project, he made a new exhaust system for his YZF-R15. Obviously, he was not keen on making just a new free flow canister. Gaurav decided to engineer the complete exhaust system which included the pipe as well as the end can.

Getting help from some local mechanics for the labour work, Gaurav managed to make an exhaust system for his bike which he felt was good enough to kill the stock R15 in straight line acceleration as well as top speed. So we decided to hook up our performance testing equipment on his modified bike and gauge its performance against the stock R15.

Looking at the exhaust, you can immediately make out that this one is a bit smaller than the stock exhaust. However, it has the same cap on it that is found on the stock one making it look more familiar to a layman’s eye. Leaving aside the looks, I decided to do a couple of performance runs on the bike. The second run itself gave a 0-60km/h timing of 4.5 seconds. Just a new exhaust system has trimmed off more than over half a second in the 0-60km/h acceleration run. Even the 0-100km/h run showed us that the modified R15 managed the sprint in 12.5 seconds as against 13.2 seconds of the stock bike. As far as top speed is concerned, the bike recorded a top whack of 134km/h on the equipment. A slightly longer straight with lesser traffic to bother about would have raised the top speed further is what we felt looking at the few more revs to go in the top gear.

This rise in performance of the R15 can be experienced from around 5000rpm unlike the stock bike which comes alive just after 7500rpm. The midrange of the bike was much stronger than the stock R15 which I am sure will make a positive difference for city riding. Also, the sound note from the free flow system is louder than the stock one yet much better and quieter than the other locally made exhaust systems.

 

This exhaust system for your R15 can be bought at a humble price of Rs 9000 (includes the pipe and the canister) Contact: +91 9819003637

 

Saeed Akhtar is in a stupor as he goes one up on Vin Diesel with a steroid injected Karizma
Photography by Sanjay Raikar

 

A few decades back, performance enhancement was a term very few bikers in India were familiar with. The racing community was in its nascent stage and most bikers were satisfied with whatever miniscule performance was on offer. But as time progressed, bikers – like all humans – began demanding more from their steeds and started getting familiar with acronyms like NFS, TFATF and thus NOS.

Nitrous oxide systems are still regarded as an arcane art even in most tuning circles. Movies like the Fast and the Furious series, Dhoom and the Need for Speed games franchise have elevated the NOS acronym to something of a cult yet they are also notorious for wrecked powertrains and giant fireballs. First used during World War II in Luftwaffe aircrafts to boost the power output, Nitrous Oxide or N20 is a colourless non-flammable gas with a pleasant, slightly sweet odour and taste. It is popularly known as laughing gas because of the euphoria it induces in humans. Amongst petrolheads too, it induces euphoria but of a slightly different sort. Although it is not flammable in itself, its ability to deliver more oxygen by breaking down at elevated temperatures makes it an excellent catalyst for burning Saudi Arabia’s finest in the fastest possible time. The gas is stored in liquid form and injected either into the intake manifold or right before the cylinder (direct port injection) whereupon its expansion causes more air/fuel mixture to enter the cylinder. By this simple expedient of burning more fuel, very large power gains are possible provided you know how much stress your machine can handle. The increased cylinder pressures caused by nitrous induction have to be harnessed very carefully otherwise you risk blowing off your valves or melting the piston to a molten lump in your enthusiasm. No kidding.

BIKE India has tested NOS kits fitted on the Yamaha Enticer pseudo-cruiser as well as on the screaming Pulsar 180 third gen in the past. This misty morning we ushered in Diwali with the best firecracker we could lay our hands on – a modified Hero Honda Karizma with NOS and a reworked, longer gearing. The blue Karizma featured here is fitted with a 300ml nitrous oxide can that is sufficient to propel the 223cc bike forward for 15 short bursts. Harish Chellani, the owner, importer and installer of the NOS kit, will happily supply you bigger containers for more bursts if you don’t fancy visiting the refill shop too often. Speaking of refills, a 300ml refill will cost you only 150 bucks – a fair bargain considering the power that’s on offer. Harish has found a convenient location for the cylinder in the sari guard, from where a silver coated pipe carries the gas to the inlet manifold. Call it direct injection if you will. A toggle switch, resembling the ones used in old spy movies, that controls the NOX induction is mounted inside the fairing. With it, in the on position, the horn switch ditches its usual duty as a traffic shredder and assumes the role of a catapult. Harish hasn’t fiddled with the carb yet but he has two jets of different sizes for varying amounts of nitrous boost, depending on your craving. The smaller one was on the bike and the bigger one was, well, in his friend’s pocket. Bugger!

The rules are clear and simple, you can employ nitrous boost in every gear provided the rpm is above 4000 and the throttle is fully wrung to the stop. On my first run on the expressway, I gingerly pressed the horn button while in the second gear and braced myself for the kick in the back. Although it didn’t quite qualify as a kick, the tacho needle went berserk and raced up the limiter very fast – too fast for a 223cc bike! Approaching the limiter, the engine roared like it was going to blast its innards out if I persisted anymore. Hmmm. . . . must be time to wind up another gear. A momentary slowing down of pace and it was mayhem again as I pressed the horn button hard enough to snap it off its mounting. No time for glancing down at the speedo or tacho, my eyes were too busy watching out for innocent and beautiful belles with pitchers straying on the tarmac as well as four-legged creatures answering nature’s call right in the middle of NHAI’s crowning glory. If you have not ridden anything on the far side of a Ninja 250 or a RD350, the acceleration even with the smaller jet and longer gearing (14 teeth front/38 teeth rear sprocket a opposed to 13/40 stock sprockets) is astounding. The noise too! Even in higher gears, the bike pulls with such alacrity, that it is very easy to cross sane speeds unless you are also keeping an eye on the speedo. Which frankly, we won’t recommend. Whereas this Karizma (with a reworked gearing) does the 0-60km/h run in 4.77sec sans the laughing gas, it does the same run in 3.87sec flat with it. The 100km/h mark was done and dusted in 10.06sec with NOS. Without it, the bike touches the ton at a relatively slow 13.10sec. Lack of saddle time and horrendous traffic prevented us from taking the top speed estimate, although it must be fairly high up on the stock bike. Sorry.

The downsides of this manic exercise are that it becomes very difficult to resist a dab on the horn button every time you see an open stretch of tarmac. If you are ready to compromise a fair bit on the longevity front for some adrenalin, go right ahead and install it – it’s worth every precious penny. Whether it should be used on public roads is an issue only your heart can decide. However, continuous high revving will eventually take its toll on the bike. A small price to pay, we reckon, considering the excitement that’s on offer.

The NOS cylinder finds a convenient home in the saree guard	The sprocketing has been revised for a higher top speed	Faster acceleration and higher top speed hand in hand, gimme more.

The leading performance parts maker from U.S.A, Two Brothers Racing introduce a special exhaust system designed specifically for the Yamaha R15. Adhish Alawani finds out just how good it is

The YZF-R15 was launched in the Indian market more than a year ago and it raised the standard of sport biking in the country to a new level. The country’s performance motorcycle scene has been scaling new heights ever since. An appreciable change that is currently being witnessed in the Indian biker is that he has started preferring performance upgrades to the cosmetic ones these days. As a result, various options along these lines are being explored today.

After testing the performance kit from Daytona and a locally made exhaust system for the R15 in our previous issues, what we have here is the latest offering from Two Brothers Racing (TBR), USA. Specially designed for the YZF-R15, this exhaust system comes from the US manufacturer who has been making high performance racing canisters and full exhaust systems across the global range of street motorcycles, motocrossers and ATVs.

The end can of the exhaust system offered by TBR features their patented lightweight, thin wall die-cast aluminum inlets and outlets. The vertical oval canister from the M-2 series comes with the V.A.L.E. (Variable Axis Locking Exhaust) system – a method in which the muffler canister is attached to the exhaust tube without the use of welding. With the V.A.L.E. systems, the muffler assembly – the exhaust tube and canister – can be positioned perfectly on the bike before all the mounting hardware is fully tightened. Once the canister and exhaust tubes are properly aligned, the V.A.L.E. assembly locks the muffler canister to the exhaust tube assuring a perfect, leak free fit. A lot of technical science, is it? Okay, let’s talk the language a biker understands. Performance. With the data logging equipment mounted on the R15, we decided to do 0-100km/h runs on the stock bike as well as the one with the TBR system. Very frankly, we didn’t need the data logger to tell us that there was a noticeable rise in the performance of the Yammie. The R15 started pulling pretty strongly right from 5000rpm unlike the stock model which does the job from around 7000rpm. The midrange of the bike feels much stronger than the stock one making it a more tractable machine for city use. If one has to speak in terms of accurate timings then with the TBR exhaust system, the R15 managed 0-60km/h in 4.15 seconds as against 4.9 seconds of the stock bike. The R15 crossed the three digit mark in a mere 11.76 seconds with TBR which is much quicker as compared to 13.04 seconds with the stock exhaust. With an improvement of 1.28 seconds in the 0-100km/h run, the TBR system definitely does the job it is intended to do. The weight of the new exhaust system is just 2.09 kg, almost a whopping 3.5 kg lesser than the stock one, which helps in boosting performance to a considerable extent.

Apart from the fantastic performance offered by the exhaust system, there is no doubt about the cosmetics of the canister. The brilliant finishing and the upmarket styling of the muffler, like the ones on Fireblades and R1s, will definitely add glamour to your bike. However, being a pure racing product, the TBR system is loud and can technically be used only on the racetrack. Riding the R15 with this system on a daily basis in the city is not really going to be comfortable for anyone’s ears. The company claims that they will soon be coming out with the Power Tip accessory for the exhaust that will help in suppressing the sound emission to a great extent with a negligible reduction in the performance. Apart from the loud nature of the exhaust, the price is going to be another negative aspect. At Rs 19,990, the exhaust is quite expensive but then, it’s the racing performance that we are talking about and every bit of it comes at a price – especially when it is from the masters who have been delivering amazing products for quite some time in the international market. The TBR exhaust for the R15 will also be available with csarbon or titanium canisters (Rs 27,500).

Full System The kit will include the pipe as well as the canister along with all the nuts and bolts and accessories for fitment	Muffler Cap The canister comes with a neatly crafted magnesium cap

A cool, custom built cruiser based on the RD350
Story Mihir Gadre

Shirish Kakatikar, a young lad from Belgaum and a jeweler by profession, has a passion for big cruiser bikes. He has always dreamt of owning a big cruising machine. His dream seemed to be materializing when he approached AMC (Amit Moto Co) run by Amit Sawant, a mechanic who specializes in modifying bikes. At AMC, Amit and his team started working on a Yamaha RD350.

Selecting the RD as the donor bike was definitely the right choice as the 32bhp, two-stroke engine had more than enough power to propel a heavy cruiser. Moreover, the sonorous exhaust note of the twin cylinders would make sure that the finished product would grab attention on the road with ease. The Vulcan, as Shirish calls his customized bike, is full of exquisitely detailed, eye catching features. It features a custom made tank with twin lids like the Indian Chief, a chrome plated instrument panel and a flame paint job, which is a common sight on most custom bikes.

A lot of modifications had to be made in order to fit a wide Bridgestone 190/17R tyre at the rear. A rim that could house this wide tyre was sourced from the Tata Sumo and was altered by taking off the center portion and making a provision for the hub and spokes. A special swingarm that was wide enough to house the wheel along with a custom made wide fender had to be fabricated. Even the chassis had to be widened at the rear to house the huge rear fender. The paint job on both the fenders and the tank is another center of attraction. The flame job on the bike is the reason it is named after the Roman God of Fire, Vulcan. The chrome plated engine, the rims, the forks, the footrest assembly, the rear shocks and the wide handlebar make the bike more attractive.

The Vulcan features a host of other modifications as well. The clutch operation system is changed from a normal cable system to a hydraulic one, using the hydraulic pump of a Honda bought from a junkyard, which was found to be working fine on the RD. The same bike’s front disc’s hydraulic pump was picked up to do duty here. The ignition system has been changed from the normal point setting type to an electronic ignition using separate coils for each cylinder. The front and rear discs are taken from the Honda Unicorn, the front caliper is of a Pulsar and the rear caliper is of some sports bike, bought from a junkyard.

The twin exhaust pipes are merged into a single pipe, firing out sound notes somewhat similar to a Harley. But using the exhaust of a four-stroke motorcycle on a two-stroke engine doesn’t make it a technically sound proposition. The front footrests, the brakes and the gearshift paddle have been sourced from the Yamaha Enticer. The stock front forks have been raised by two inches. The rear suspension is taken from the Bajaj Eliminator. The front tyre is a Dunlop with a 120mm wide section. The head lamp and the speedometer are taken from the Bajaj Eliminator. The Vulcan, like all custom motorcycles, offers the ultimate poser value and guarantees exclusivity that can’t be had with any mass produced bike.

RD350 engine with electronic ignition	Rear disc from the Unicorn	RD350 engine with electronic ignition