Virginal rebuild project (a.k.a 'pain in the arse')

[Whosthedaddy]

This will hopefully be a tale of a strip and rebuild rather than a strip and sale of miscellaneous parts on eBay .

I am talking about my newly acquired Yamaha FZR 600 (’89 model) which I preceded to crash only minutes after buying it for £600.

https://www.bikechatforums.com/files/f7_0.jpg

For a long time now I would have loved to have either built something from scratch like a kit car or restored a project, this seems the best of both worlds. The bike is broken, so what on earth could I do to make it worse . I have all the best intentions of striping it down, fixing / replacing the broken / damaged or worn parts and return it to the glorious sports bike it so rightly deserves to be.

Upon initial inspection, the damage appeared to consist of the following:

Broken crank case number 2

https://www.bikechatforums.com/files/fzr600_024.jpg

Broken and cracked right hand lower fairing

https://www.bikechatforums.com/files/fzr600_002_142.jpg

Scratched front brake lever
Scratched right hand bar end
Cracked and broken screen

It only took me a little sourcing on eBay to find a FZR for breaking that had a replacement engine cover, cost me £30 from Kev at South Devon Motorcycle Spares (the very same people that bought my ZXR for breaking).

The only problem seemed to be was undoing all the bolts, they are 17 years old and have probably never been undone since leaving the Yamaha factory. With copious amounts of WD40, and a new set of Allen keys (£3.99 from Halfords ) the final bolt moved and the case was off. The replacement one had a half decent gasket already left on, so in with some oil and it started 1st time, and more importantly, so far no leaks . It was also at this time that I realised that I could almost press on the handle bars and make the suspension at the front bottom out, I think the seals have gone.

As the bike was running, I thought it was about time for a ride around the block, the damn bike wouldn’t move backwards, and the little distance it would move was extremely hard work. Knocked into 1st gear, the bike would run forwards fine, but not backwards. The rear brake maybe? The chain and sprockets? The wheel bearings? Who knows .

As the bike was a non mover, the destruction began

It didn’t take long for the following to be removed:

Front fairings
Upper fairing
Headlights
Indicators
Seat
Rear lights and tail unit Inc number plate
Under tray
Battery box and rear electric connectors
Exhaust
Rear hangers
Chain guard
Both heel plates
Header tank

https://www.bikechatforums.com/files/fzr600_009_142.jpg

The under tray was an absolute bitch to remove as the position of one of the nuts and the fact that it had almost cross threaded itself coming off meaning that it would just spin and spin, after 30 minutes and a lot of swearing, it was off.

My attention was turned to the rear brake. The foot pedal (lever type thingy) has a lot of sideways play which may be what is binding the rear brake on all the time I have so far attempted to remove the rear brake calliper so as to be able to free wheel the bike backwards with no resistance. Again, the bolts are super tight and hard to undo, and one has been rounded over, so will have to break out the monkey wrench (when I get one )

Jobs for the weekend include:

Drain the petrol tank
Remove the tank cover
Remove the tank
Remove the rear brake calliper
Remove the down pipes

Jack the bike up on axle stands and:

Remove the rear wheel
Remove the swing arm and rear suspension

I feel that I will work from the back forwards as I have already started there and then have a go at removing the front forks and replace the seals, if not chuck them in the car and give them tom the garage to fix

Will post pics when the destruction begins in earnest.
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Current : MSX 125 Past : CBR 900RR Monkeybike : c50 LAC : ZXR750 H2 : FZR600 : ZX7R P3 : YW100 : TRX850: Trophy 900 T309 : GSXR 600 L0: Monkeybike : XJ6S Whosthedaddy

[Whosthedaddy]

I am unsure to the paint scheme. If I get a new body kit, 2nd hand fairings or bodge (sorry repair and restore) my own damage panels, they will need a dab of colour to match the rest of the bike, so what should it be?

I am open to suggestions

I quite fancy painting the frame black, so what colour would go with a black frame?

I dont quite want to start a thread on 'please photoshop my bike' but, if you have some spare time and a bit of imagination then feel free.

I quite like the idea of a bright orange (BCF stylee )
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Current : MSX 125 Past : CBR 900RR Monkeybike : c50 LAC : ZXR750 H2 : FZR600 : ZX7R P3 : YW100 : TRX850: Trophy 900 T309 : GSXR 600 L0: Monkeybike : XJ6S Whosthedaddy

[palmer]

If you have the time/tools, id say polish the frame.
Spray the plastics gloss black.
White decals.
Gloss black wheels.
Possibly red rim tape.

Plan to do it, simple, but if done well looks pretty sweet.

[Whosthedaddy]

Sounded good till the rim tape

Black and white would look cool.
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Current : MSX 125 Past : CBR 900RR Monkeybike : c50 LAC : ZXR750 H2 : FZR600 : ZX7R P3 : YW100 : TRX850: Trophy 900 T309 : GSXR 600 L0: Monkeybike : XJ6S Whosthedaddy

[Bullet]

polished frames do look fly its true, but to do the job right will take you ages, and then be prepared to NEVER let it get wet, if it lives outside then dont polish it or youl regret it! as youl be out there with the brasso all the time and have a constant black bogey problem also unless the finish on the frame is damaged i wouldnt bother with the powdercoating either.

as for a paint scheme gota be Red & white on a yamaha for the win!

good luck with it
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nonstop unicorns vomiting sunshine pills into a rainbow toilet
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past: ZXR750 J1, K1 & H1, GPX600R, Yamaha Radian. present: ZXR750 J2, SP-1, CB350

[JonT]

I so had to read the name of the topic twice :p

[ram_doom]

Nice to see your starting to get it back to working order as for paint, what about classic yamaha speed blocks https://www.bikehps.com/acatalog/Yamaha05-50thAnniversary.jpg
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TL1000s, KDX200

[Whosthedaddy]

Yellow and black's a good colour combo and a Yamaha one at that

Second day of destruction

After having a boot full of parts for the past couple of days, I finally get round to putting them in the parents garage. It was a nice excuse to nick the axle stands, trolley jack and some more wrenches as well .

My 1st agenda was to remove the tank, maybe the exhaust down pipes to jack under the engine and remove the rear wheel. I had fashioned together a syringe, blood giving sets and a 3 way tap to drain the petrol from the tank to make it a little easier to handle. After draining 6 pints off I started to get a little dizzy from the fumes

So, fuel tank emptier, the gas cap was off, petrol tank cover was next. I have to admit, what was underneath was a disappointment compared to the naked inline 4 of a Kawasaki engine What was being hidden was a black turd of a fuel tank and the air filter and box. I thought it would be easy to now unbolt the exposed fuel tank, but no the tank appeared to be connected to the fuel filter, fuel pump and god knows what else. I couldn’t see the attachments to the fuel switch so I have left the tank insitu for now.

After some careful unplugging of electric connections my attention was turned to the cooling system. The pipes were easy enough to remove, but the radiator was an absolute bastard. I undone the couple of bolts securing it to the mounting brackets and then all that was holding it to the bike was the electrical connection for the fan.

https://www.bikechatforums.com/files/fzr600_028.jpg

Do you think I could thread this through the engine bay and free the rad?, No, the small hole is too tight for it to pass and without stripping out even more electric connections to allow removal of the engine shield, the radiator can stay on the bike.

What crap came out when the pipes were removed was turd brown and smelt just as bad :ill: I suspected that the water may be manky looking as the header tank was brown and crusty.

https://www.bikechatforums.com/files/fzr600_025.jpg

Not sure whether the previous owners had actually changed the water and used anti freeze or not, I suspect not.

2 jobs, 2 unsuccessful attempts

The dials and Speedo cable were easy enough to remove, and the mounting bars soon followed. It looks quite strange without any instruments and lights up front, not sure on turning it into a street fighter just yet If the body work doesn’t go back on, then it may be left naked.

With the radiator still swinging around at the front of the bike, I give up on the idea of jacking under the down pipes, so it was down to shear brute force and a lot of grimacing The neighbours must have thought we were mad. The missus was a stride and leaning up against the tank supporting the bikes weight by holding the bars and I am at the back, lifting the bike by the bare frame and kicking the stands under the swing arm. I don’t think that removing the fuel made it that much lighter, but maybe just enough

After thinking it was a binding rear brake, the back wheel spun around quite nicely with little effort needed So, next job, remove the rear wheel.

The rear brake calliper nuts were too solid to undo, and as I couldn’t remove a slit pin on the support arm, a bit of initiative was used (I think this will come back and bite me in the ass). The wheels spindle was undone and knocked through to allow just enough movement forwards and downwards to get the brake calliper off the disc and the chain off the sprocket.

However, neither happened

It took some more brute force and a lot of jiggling to get both off.

The rear wheel looks in good condition apart from maybe a small stone in the tyre.
Wheel bearings just need a good clean and re-greasing
Sprocket looks good, just a little dirty. One of the nuts securing the sprocket to the wheel cross threaded a little when unscrewed, so may need a new nut or two.
Rear brake disc appears ok, no lip on the leading edge.

https://www.bikechatforums.com/files/fzr600_030.jpg

I want to remove the swing arm and shock next. They are both covered in shite and the swing arms scratched and dented like its been down the road before

Its funny what you can find when removing things, maybe an HPI check would have been beneficial
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Current : MSX 125 Past : CBR 900RR Monkeybike : c50 LAC : ZXR750 H2 : FZR600 : ZX7R P3 : YW100 : TRX850: Trophy 900 T309 : GSXR 600 L0: Monkeybike : XJ6S Whosthedaddy

[Whosthedaddy]

Check out the 'tide' marks on the front forks:

https://www.bikechatforums.com/files/fzr600_033.jpg

The upper one was caused by me and all my 12 stone leaning and bouncing on the bars. I suspect they is'nt much oil left in them if they can be compressed this much

New fork seals were delivered today, only £6 off ebay
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Current : MSX 125 Past : CBR 900RR Monkeybike : c50 LAC : ZXR750 H2 : FZR600 : ZX7R P3 : YW100 : TRX850: Trophy 900 T309 : GSXR 600 L0: Monkeybike : XJ6S Whosthedaddy

[chalky143]

hope it goes well m8
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Current bike :: sv650 minitwin race bike
Previous bikes::cbr600 steelie race bike, 1989 Honda vfr750f, 2013 Honda fireblade, 2013 Ducati multistrata 1200s, 2012 Triumph street triple R, 1999 yamaha r6, vfr 800, ducati 600ss, vfr 400x2, ntv 650, bandit 600, cagiva mito 125, aprilia rs 50, honda c90x2, honda hornet 600x2, cbr 600, aprilia rx50, suzuki katana
My bike pics: https://www.bikepics.com/members/chalky143/

[Hotdog]

How did you crash it ?


____________________
He's a gentleman, a scholar, he's an-acrobat, he's the one and only truly original.......
Hotdog....(Defender of the weak, the poor and the innocent)
He's The Ace - He's Amazing...He's the Strongest... He's The Quickest.... He's The Best!

[Whosthedaddy]

To be honest, the more I think about it, the more I'm unsure

https://www.bikechatforums.com/viewtopic.php?t=86921
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Current : MSX 125 Past : CBR 900RR Monkeybike : c50 LAC : ZXR750 H2 : FZR600 : ZX7R P3 : YW100 : TRX850: Trophy 900 T309 : GSXR 600 L0: Monkeybike : XJ6S Whosthedaddy

[Hotdog]

Shouldn't you have found out what was causing the running problems before you took it apart ?

If it's still playing up after the refurb it could spit you off again.

Hotdog.
____________________
He's a gentleman, a scholar, he's an-acrobat, he's the one and only truly original.......
Hotdog....(Defender of the weak, the poor and the innocent)
He's The Ace - He's Amazing...He's the Strongest... He's The Quickest.... He's The Best!

[Whosthedaddy]

True.

The bike started like a dream after the new cover was on, but the bike felt stiff and was making a clicky type of noise when rolled, so a strip and a clean seemed a good idea to see whats what.
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Current : MSX 125 Past : CBR 900RR Monkeybike : c50 LAC : ZXR750 H2 : FZR600 : ZX7R P3 : YW100 : TRX850: Trophy 900 T309 : GSXR 600 L0: Monkeybike : XJ6S Whosthedaddy

[McGee]

Cant wait to see it all finished
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◙◙► K6 GSXR 600 ◄◙◙◙◙► K5 GSXR 1000 ◄◙◙◙◙► K5 GSXR 600 ◄◙◙◙◙► 96 RF600r ◄◙◙
◄◙◙◙◙◙◙◙◙◙◙◙◙◙◙◙◙◙◙◙◙◙◙◙►◄◙◙◙◙◙◙◙◙◙◙◙◙◙◙◙◙◙◙◙◙◙◙◙►◄◙◙◙◙◙◙◙◙◙◙◙◙◙◙◙◙◙◙◙◙◙◙◙►
Its pronounced Jixxer!

[Whosthedaddy]

Had a couple of hours spare this morning before work and am really keen on actually starting to do something to the bike rather than hust stripping random parts. However, the swing arm is my little bug bear, its rusty and slightly dented and scuffed.So its seems logical to restore and clean it before putting the rear of the bike back together.

After 10 or 15 minutes, the swing arm and rear shock are out. The amount of thick grease on them is unbelievable.

https://www.bikechatforums.com/files/fzr600_035.jpg

https://www.bikechatforums.com/files/fzr600_037.jpg

After a little scrubbing and brushing with a wire brush, the swingarm started to look better already, but, there is a small hole near a joint caused by rust . I had only worked on the left hand side of the pic, the difference is quite impressive even though its stilll needs quite a lot of work.

https://www.bikechatforums.com/files/fzr600_034.jpg

I was intending on filling the little indentations with body filler / repair stuff and then spraying etch primer and more likely silver paint to match the rest of the frame. If possible, the shock will get a coat of paint as well.

In the short term, I am either unable to remove parts to strip the frame down or a little scared at removing everything. I really want to ride this bike this year, so it may be a second project later .

The shite and grease on this bike will take longer to remove and clean than the replacing the various parts that have been removed

https://www.bikechatforums.com/files/fzr600_036.jpg

Does anyone have any suggestions or tips of removing thick deposits of dirt and grime?

A karma cookie will be awarded
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Current : MSX 125 Past : CBR 900RR Monkeybike : c50 LAC : ZXR750 H2 : FZR600 : ZX7R P3 : YW100 : TRX850: Trophy 900 T309 : GSXR 600 L0: Monkeybike : XJ6S Whosthedaddy

[Barry_M2]

I have this sticker kit if your interested (see pic). Dont need it now as I gave up on the FZR project and got another ZXR.

£20 delivered (All stickers are there).

You just need to spray your whole bike white!

https://i7.photobucket.com/albums/y269/Barry_mc21/Yam_M12.jpg
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ZXR750R (M2) - For the road.
CBR1000 RR4 - For the track.
https://www.bikechatforums.com/profile.php?mode=viewprofile&u=4332

[Hotdog]

Could you fit the unbraced alloy swinging arm from a slightly later fzr ?

I'm not certain when, but didn't they fit a decent alloy arm a year or two later ?

Hotdog.
____________________
He's a gentleman, a scholar, he's an-acrobat, he's the one and only truly original.......
Hotdog....(Defender of the weak, the poor and the innocent)
He's The Ace - He's Amazing...He's the Strongest... He's The Quickest.... He's The Best!

[Kram]

An R6 swinging arm will fit, (needs some spacers machined, slightly thinner) then you can get an R6 wheel, and buy decent tyres for it .

To get the tank off is really simple.

I got a Haynes manual in pdf, if you want a copy as well.

Barry, if daddy doesn't have them, i'll take them off your hands. as i need new fairings, (and the ones i can get come in white)
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FS1E -> SR125 -> CB400N -> CB650 -> FZR600 Genises -> VFR400 NC21 -> CBR900RR Fireblade -> Renault Clio 1.4

[Whosthedaddy]

I have bought a Yamaha work shop manual its nice and simple (just like me ). Not got a day off until next week so I'll have a look and see if ther tank comes off

Barry, cheers for the offer, may take you up at later date if you still have them, but low on cosmetic funds at the moment.
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Current : MSX 125 Past : CBR 900RR Monkeybike : c50 LAC : ZXR750 H2 : FZR600 : ZX7R P3 : YW100 : TRX850: Trophy 900 T309 : GSXR 600 L0: Monkeybike : XJ6S Whosthedaddy

[Whosthedaddy]

[quacker_boy]

For grease and grime...a bucket of petrol and a wire brush are you only friends.

I've just landed back in the UK and noticed it's a quid for a litre of petrol, EXTORTION!

If you want to be a cheap skate though you could always opt for thinners i guess.

Any other questions gimme a call 07900 380 989
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wizzzard wrote: Imagine God just stopping by, tidying your front room up and then quietly letting himself out again. Statisticly more likely to happen than Korn being on here.

[Barry_M2]

[Kram]

well if i can fix my low compression issues with my engine, and get it all working healthily, i will spend the £205 for new front fairings, then buy your sticker set.

but if i can' fix my engine i won't bother as i will scrap the bike
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FS1E -> SR125 -> CB400N -> CB650 -> FZR600 Genises -> VFR400 NC21 -> CBR900RR Fireblade -> Renault Clio 1.4

[ram_doom]

Paraffin makes a good degreaser...
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TL1000s, KDX200