Yam FZS600 Fazer Cylinder Head Replacement and General Clean

[0l0dom0l0]

Well since I first got my bike its been pissing oil everywhere, because some Dick has managed to snap on of the cooling fins off. When I bought the bike it was covered in gum gum, so I had no idea as to how badly the engine was damaged. Anyway after tapping the gum gum off, I was greeted with this

Turns out the same Dick welded it up, and did a very bad job of it:

https://i1183.photobucket.com/albums/x474/0l0dom0l0/DSC05543.jpg

Anyways, all is not lost, and for the £900 I paid for her, shes not that bad really :

https://i1183.photobucket.com/albums/x474/0l0dom0l0/DSC05564.jpg

After many failed attempts to plug the leak, with epoxy and what not I came to the conclusion that I was going to have to get it welded again, or get a new head. So, I searched the net and found a head that had come off a bike that had done a total of 8 thousand miles. Couldn't say no really. It was skimmed today, was a tiny bit off in the middle. A grand total of 4 thou was taken off. It really has made a hudge difference to the surface though. I should have got some pictures before it was done, but here it is after the skimming

https://i1183.photobucket.com/albums/x474/0l0dom0l0/DSC05567.jpg

I had work this morning, I got home around 2. Went straight out and got a few bits that I needed. Greases etc. Anyways, started stripping the bike this afternoon. Has gone well so far.

Here is before:

https://i1183.photobucket.com/albums/x474/0l0dom0l0/DSC05574.jpg

And after an afternoons work! :

https://i1183.photobucket.com/albums/x474/0l0dom0l0/DSC05575.jpg

Anways, tomorrow we will be taking the old head off, and inspecting everything. Hopefully it should go well .

I have on order:

Exhaust system
Exhaust gaskets
Head Gasket

Stuff I need:

Exhaust nuts.

Stuff to do:

Sort out forks,
Clean everything in sight
soak all rusted parts in vinegar

Stuff must not do:

Look at bank statement.

[CHR15]

when your taking off the head oil feed line ( rusty one that runs up the front of the block) make sure you do it with a very well fitting socket, or you'll round it off.

also, give it a good tap first, to break the rust a bit.
____________________
Turbocharged drag thing / project death weapon / GK73A
Ste: I'm not entirely sure how you'd go about verbally abusing someone with a potato but I'm sure it's possible.

[0l0dom0l0]

Thanks Chris. It the only bolt that is properly rusted up. If this feeds engine oil to the head, where does it then go after that? I cant see an oil return anywhere?

[CHR15]

return is more than likely through the cam chain tunnel.



also, when you've finished, flush the engine / radiator through with a hosepipe.

the stuff that came out mine was a horrible colour.
____________________
Turbocharged drag thing / project death weapon / GK73A
Ste: I'm not entirely sure how you'd go about verbally abusing someone with a potato but I'm sure it's possible.

[woll]

Chris i hope you mean the cooling system? Not the actual engine lol, don't want him filling the cylinders full of water.
____________________
Current Bike- Suzuki DRZ400 SM K6
Previous bikes - Derbi Senda Xtreme50r, Honda CBR 125, Kawasaki ZZR 250, Yamaha DT125R, Suzuki Bandit 600, Gas gas ec 250, Honda CBR600FW
Damaged spleen, damaged kindey, 2 popped lungs, 2 broken ribs, broken face, broken wrist and 5 back fractures... remember kids walls hurt

[CHR15]

[0l0dom0l0]

Yeah, that seems sensible.

An update of today's work:

Started off by removing anything that was in the way, the coils, fuel pump etc and the radiator had to come off.

Then took the valve cover off and started removing the camshafts:

https://i1183.photobucket.com/albums/x474/0l0dom0l0/DSC05578.jpg

I didn't manage to get any in between photos, so we just have the bike as t stands now:

https://i1183.photobucket.com/albums/x474/0l0dom0l0/DSC05584.jpg

I was surprised to find that both cams were well within the service limit though, not even 50% worn, so that's good news. Anyway here they are all layed out:

https://i1183.photobucket.com/albums/x474/0l0dom0l0/DSC05583.jpg

Old cylinder head:

https://i1183.photobucket.com/albums/x474/0l0dom0l0/DSC05581.jpg

A few things have popped up. When we were removing the cylinder head, we accidentally disturbed the barrels, and the barrel gasket. I am trying to decide if its worth replacing that too, but time is limited, and the only place I can find that stocks the gasket is Wemoto. I'm hoping it will be okay, but not really sure at the mo.

The most frustrating thing of all though, is trying to source the oil leak. There is nowhere obvious that its coming out from, and there was a fair bit coming out. It probably hasn't helped that the head gasket was installed the wrong way up, and I don't think the head bolts were torqued down correctly either. To top things up, when i turned the head upside down, a shim fell out. All of the followers had shims in though, so they had obviously decided to just leave one knocking around in the head. Overall whoever last fiddled with it, just made things worse.

To make things even better for me, I think one of my forks is slightly bent. Funnily enough its on the same side as the engine damage so me thinks something might have happened previously.

On the list for tomorrow (providing the stuff I have ordered arrives) is to install the cams in the new head outside the bike, so I can measure the valve clearances and get any new shims I need. Make a final decision as to weather the barrels are coming off and we are replacing that gasket, and start putting stuff back together. I just hope I can remember how it all went. *sigh*.

Any encouragement would be appreciated. I am a bit disheartened at the moment. My main worry being this base gasket.

Also any advice to that would be appreciated.

If I get a spare 5 mins, the fronts of the forks could do with a clean:

https://i1183.photobucket.com/albums/x474/0l0dom0l0/DSC05585.jpg

But that isn't on my priorities list at the moment!

[N cee thirty]

i'd say for piece of mind do the base gasket,as you won't wanna have to take it all apart if it leaks

order it on wemoto now,should be here tuesday

good work
____________________
'00 Aprilia RS50 > '92 Honda CG > '99 Yamaha Fazer > '91 Yamaha RXS > '79 Suzuki X5 > 01' Honda Cg > 07' Honda Cg > 82' Kawasaki Z200 > suzuki gsxr 400 gk73a > honda vfr 400 NC30 Mod 2 Passed 09/06/2011

Jewlio Iglesias wrote: I actually did vote BNP once

[CHR15]

get a close up of the 'repaired' bit.


if the loose shim rocking around in there is an example of the previous owners work I would be very surprised if the h/b were torqued down properly.
____________________
Turbocharged drag thing / project death weapon / GK73A
Ste: I'm not entirely sure how you'd go about verbally abusing someone with a potato but I'm sure it's possible.

[0l0dom0l0]

Right, I have decided to do the base gasket. For the extra few quid now, and the hour or so it will take us to do it, I think its worth it.

Wemoto can get them, but it will take at least a week to get here. The head gasket I ordered from them a last Monday, hasn't arrived yet, and I need the bike for college.

I will get a close up of the repaired bit tomorrow when I am down the garage, its a pretty shoddy repair, but I'm really confused as to where it was coming from. The cooling fin would have taken a lot of force to break off like that. The oil leak must have just been a combination of everything. The new head was well worth the money though, and its not going to hurt sticking it on there.

The build quality on these bikes is pretty darn good to be honest, especially in the engine. The barrels are in very good condition, and the pistons are too. It will be interesting to see how worn the rings are, but I doubt if there is much wear. Not bad for 30k miles.

Anyone know where I am most likely to be able to find a new base gasket? I need it asap. I have already checked with my local Yamaha dealer to no avail.

Oh btw Chris, the banjo bolt came off without to much trouble, I had given a fair few sprays of wd40, and it took a couple of hit on the spanner to free it, but it came out not to bad .

[CHR15]

[0l0dom0l0]

[CHR15]

i cant find my parts manual anywhere. fail.


anyway, it should be about 25 quid.
____________________
Turbocharged drag thing / project death weapon / GK73A
Ste: I'm not entirely sure how you'd go about verbally abusing someone with a potato but I'm sure it's possible.

[0l0dom0l0]

FOUND ONE

Am going to ring them tomorrow and see if they have it in stock and can get it to me by Tuesday.

Listen on the website at £15.

Awsome .

[0l0dom0l0]

Have ordered myself a base gasket, Oil sump gasket and a cam chain tensioner gasket too. Should all be here Wednesday.

The barrels came off without to much trouble, a couple of the screws that hold the coolant return on the front were pretty stiff, but they came off after a few squirts of WD40.

The gasket underneath wasn't to bad. At least it had been installed the correct way up!!

Here is the bike atm:

https://i1183.photobucket.com/albums/x474/0l0dom0l0/DSC05593.jpg

The barrels are in fantastic condition, no scoring, and you can't even feel any wear lines either. The rings looked a little worn, but were still very springy. A couple of photos:

https://i1183.photobucket.com/albums/x474/0l0dom0l0/DSC05589.jpg

https://i1183.photobucket.com/albums/x474/0l0dom0l0/DSC05588.jpg

https://i1183.photobucket.com/albums/x474/0l0dom0l0/DSC05590.jpg

I was pretty sure that the sump was leaking a little bit around the edges. I had ordered myself a new sump gasket and started cleaning up the sump. Its not perfect, but I figured on the first wet ride it was going to get all shitty anyway. Then I was interrupted by a large box arriving, containing this

https://i1183.photobucket.com/albums/x474/0l0dom0l0/DSC05592.jpg

And the clean sump:

https://i1183.photobucket.com/albums/x474/0l0dom0l0/DSC05591.jpg

I then wanted to test the fan and thermo switch. I have never heard the fan come on and so was concerned they were broken. A quick test revealed that they both were working correctly, so we just put it down to corroded connections.

Dads taking Friday off by which time everything should be here we need to put it all back together again. There isn't really a lot more I can do in the mean time apart from clean a few bits up.

[69.9mph]

Good job so far, I think changing the base gasket was a good decision if it been disturbed.

What make are the downpipes?

[0l0dom0l0]

[Noxious89123]

Looking good. Are the bits of foam on the levers to stop you impaling your head on them?
____________________
'06 Honda CBR125RW-6 ~ '00 Honda CBR600F-Y ~ '07 Honda CBR600RR-7 ~ Bikeless
'53 Ford Ka 1.3 ~ '03 Vauxhall Astra SRi 1.8 ~ '52 Vauxhall Astra SRi 2.2 ~ '53 Vauxhall Astra GSi

[0l0dom0l0]

[Noxious89123]

Ha, been there, done that.
____________________
'06 Honda CBR125RW-6 ~ '00 Honda CBR600F-Y ~ '07 Honda CBR600RR-7 ~ Bikeless
'53 Ford Ka 1.3 ~ '03 Vauxhall Astra SRi 1.8 ~ '52 Vauxhall Astra SRi 2.2 ~ '53 Vauxhall Astra GSi

[L4Isoside]

[0l0dom0l0]

It wont be long until my dad does the same .

It was also quite funny watching him pick up the fan switch that we had been cooking on the stove to test it. That looked rather painful

[blurredman]

Hope you're not going to eat that pot noodle. It has oil in it
____________________
CBT: 12/06/10, Theory: 22/09/10, Module 1: 09/11/10, Module 2: 19/01/11
Past: 1991 Honda CG125BR-J, 1992 (1980) Honda XL125S, 1996 Kawasaki GPZ500S, 1979 MZ TS150.
Current: 1973 MZ ES250/2 - 18k, 1979 Suzuki TS185ER - 10k, 1981 Honda CX500B - 91k, 1987 MZ ETZ250 (295cc) - 40k, 1989 MZ ETZ251 - 51k.

[0l0dom0l0]

[0l0dom0l0]

Right, I managed to get a little done today. I had work this morning, came home to a parcel for moi. Was a bit annoyed as all the gaskets should have arrived today, but I only have the head gasket from wemoto. I am a bit dissapointed, after waiting 10 days for it to arrive, its not even a genuine Yamaha one. Any ways, its written in Italian, so its probably from the same factory.

https://i1183.photobucket.com/albums/x474/0l0dom0l0/DSC05595.jpg

Then went down the garage, cleaned up the residue from the knackered sump gasket on the bottom of the engine. Didn't manage to get a photo, but when the sump gasket hopefully comes tomorrow, I can put it back on.

I then had a look at the state of my swing arm. I was there when I got my rear tyre done, and knew it was disgusting, so I decided to clean it. I had never taken a rear wheel off before, but I watched my tyre get changed and it didn't look to bad. Got the rear wheel off, and set about cleaning it. I would like to thank the person that created GUNK. It has to be the best stuff in the world for removing shit as I found out today. Anyways, here is a picture of my very shiny swing arm .

https://i1183.photobucket.com/albums/x474/0l0dom0l0/DSC05596.jpg

And a very nice clean shock :

https://i1183.photobucket.com/albums/x474/0l0dom0l0/DSC05597.jpg

I had ago at the front forks the other day. I used one of those green scourer pad things, and a bit of 3 in one. It smoothed them out, but they need a proper polish.

https://i1183.photobucket.com/albums/x474/0l0dom0l0/DSC05598.jpg

I have left some of the bolts in vinegar to soak over night to get rid of the surface rust. Seems to be working well, but my god it smells horrible!

Random pic:

https://i1183.photobucket.com/albums/x474/0l0dom0l0/DSC05599.jpg

If the other gaskets don't come tomorrow we are pretty screwed. I'm desperately waiting for the base gasket to come as we can't do anything until it does.