5 years update : Vacuum Sync/Radiator replacement/Coolant replacement/Brake fluid replacement
So as explained in the previous post, the R3 had some planned maintenance works which was decided to be done as the motorcycle will now complete 5 years in the coming December. It was more like a preventive measure than waiting for parts to fail and then replace. We planned to do this as a DIY from a friends home in Cochin and Bhpian @krishnaprasadgg joined me on my way from Calicut to Cochin, yesterday. His YZF R1 also had some planned works and this was also carried out yesterday and documented here :
https://www.team-bhp.com/forum/super...ml#post4900872 (Review: My Yamaha R1 (WGP 50th Anniversary Edition)).
We reached Cochin before 8 and started the work as soon as the bikes cooled down.
Starting pic
On the paddock and ready to be stripped
Stripped
Fairings on the floor.
So here are the planned works to be done :
1. Radiator replacement and coolant flush+replacement.
2. Spark plug swap and throttle body vacuum sync.
3. Brake fluid replacement.
The engine oil and oil filter had run just around 1500kms and it was deemed not necessary to replace and will only do it at the planned 5000kms. One major replacement missed is the air filter replacement. Apparently, Yamaha isn't sending R3 air filters to Kerala for the past 6 months. So I need to plan something else for this or look at some Bangalore showrooms if anyone has it. Mine is due for replacement but this part scarcity for such an important part is poor from Yamaha India's side. Hope things would be sorted out soon.
1. Radiator replacement along with coolant.
This was primarily done because of a dent on the radiator. This apparently happened with Bangalore wheels service center, Rajajinagar because that is the only place the bike went to service before shifting works to Highlander, HSR Layout. Why I am sure of this is, there was no scratches on the fairing, so once they removed the fairing for some work, the bike might have accidentally toppled(Maybe it jumped out of the paddock) and hit the left side of the radiator, causing damage to it. This could be the reason why the fairing doesn't have any scratches. This was noted when we removed the fairing from Highlander and they showed me the damage. It wasn't significant and I rode with it for almost 2 years now, but somewhere in my mind it was clear that the coolant flow would be interrupted thanks to the dent and hence decided to replace it. Along with this, the coolant reservoir and two small tubes of which one takes coolant to the radiator and the other being the overflow tube, was also replaced. Coolant reservoir has a history of cracking for most owners around the 4 year mark and that is one thing I didn't want to take a chance on!
Costs involved: Radiator : Rs.3750. Hoses: Under Rs.100. Coolant Reservoir: Rs.140
The car backseat full of parts. Most are rubber bushes and clips, which had separate packings.
The old coolant reservoir with a lot of muck inside it. Cleaning could be done, but since this part is relatively cheaper and has a history of cracking, I replaced it with a new one.
The new radiator
The dent on the left side of the old radiator, thanks to Yamaha service center and they never informed me(of course they wont!)
The new one along with the old one. Marked are the mounting points and see how it got bend on the impact. I really don't know what they did with the bike. But the bike never stayed at this service center for more than 8 hours.
Old coolant drained out and flushed with distilled water.
The new radiator with fan fitted. Both are made in Indonesia by TRAD.
The new coolant reservoir.
2. Throttle body Sync and spark plug replacement
Once the radiator works were done, settled and tested, we now moved to plugs and vacuum sync. Vacuum sync is something which most ignores or doesn't care of, or even knows of. Balancing the throttle body ensures that each cylinder has the same vacuum. This usually makes both of the cylinders to respond and act equally and also makes the bike run smoother as one or more cylinders wont surge or stumble. Service centers usually does this when bikes have snatchy pickup or irregular idle, but Yamaha recommends to check the vacuum at every 6000kms which itself is an overkill. I guess my time of 5 years/33,000kms was too late as well. Ideal time would be every 15k kms, at least.
Make shift arrangement for cables from throttle body to come out, so tank had to be lifted a bit.
Its good to adjust the vacuum sync with new plugs and new air filter. Air filter was not available anywhere, so kept the old one now. The plugs were replaced with new stock ones, purchased from Yamaha.
Used a torque wrench for almost all the bolts and used the service manual to know the recommended torque. Plugs tightened at 13nm of torque.
Team-BHPian @krishnaprasadgg referring the R3 service manual on the lap to make sure we aren't missing on anything.
What the service manual says.
Before the sync. Notice the slight difference in the vacuum of the cylinders. We had the perfect tool for the perfect job.
After the adjustment. Almost similar now.
3. Brake fluid replacement and anti seize compound application.
Nothing much here, I keep an interval of 2 years for coolant and brake fluid replacement and it was time to do it. Used dot 4 fluid from Liqui Moly and flushed out the old oil, bled the lines and the brakes are superb as before with a good assist from Spiegler brake lines.
The Dot 4 brake fluid from Liqui Moly.
We applied Anti Seize compound to almost all the nuts and bolts we removed.
The brake pads still have life left. The pads and the pistons were cleaned and the pins were greased.
So finally everything was done and test rode the bike without fairings installed. This was to see if the bike took in more coolant so that we can add it in the radiator. All the checks were done and this is how the bike looked.
Everything mounted back.
The view of the new radiator.
Pitstop on the return run, late evening. That's me
Trip meter after the ride.