FZR project

[Tristan.]

My FZR is getting a bit shocking, I have quite a few plans for it, but I won't go through them yet. Need to wait for some details of parts etc.

Anyway, I started the stripdown yesterday, and got some pictures

Year and a half ago she started off as this
https://i35.photobucket.com/albums/d170/tristanthe/PIC_0006-2.jpg
and then went to this about a year ago.
https://i39.tinypic.com/2ups177.jpg
and got a lot dirtier over the year.
First off tank, seats and exhaust off
https://i43.tinypic.com/jjmkx1.jpg
https://i44.tinypic.com/v5b8jn.jpg
only two snapped studs
https://i43.tinypic.com/1253sz9.jpg
https://i39.tinypic.com/fxard0.jpg
it is stainless steel, honest.

Anyway then I phoned a mate, to get it up on blocks, he was doing university or something gay so I sorta lifted it on the sidestand and popped the plank under, tbh I'm not sure how I did it, but it worked.
https://i43.tinypic.com/9lfz8g.jpg
https://i44.tinypic.com/x5xueq.jpg

Next I wanted the engine and frame apart, two bolts at the back, then 4 M10 Allen bolts bolted into the heads. Couldnt find my 10 mill allen key thingy for my ratchet, so I went to use a T bar allen key. Which fucked it up quite quickly. So I used a dremel to grind the handle off, so I coule put the shaft in a 10mill socket. Unfortunatley I didn't think this through
https://i43.tinypic.com/2a50oci.jpg
and covered myself in melted rubber and plastic.
Anyway, that worked, and I now had to lift the frame off the engine, on my own.

I decided to use the garage roof beams, and bike chains.
https://i42.tinypic.com/29ysch4.jpg
The intention was that I could simoultaniously lift up at the back and pull down on the chain. It didn't really work. So I went to plan B
https://i42.tinypic.com/2qdcu1v.jpg
I figured if I hung something heavy on the front chain, then just lifted the bike then the weight and friction would keep it lifted, meaning I could just lift, rather than lifting and supporting it, sooo:
https://i40.tinypic.com/w2je36.jpg
Again it didn't work, The beams where far too rough, so even though I could lift the back end a foot or so up the chains didnt take up the slack, and I couldnt lift it high enough to lift it right over. So I decided to take bits off, to make it lighter, which was very annoying, as my intention for the strip was, to keep stuff together wherever possible, my experience is that when you take it into a million bits it never goes together again, and if it does, you lose half the bits. It was also annoying, because it meant taking the front end off with a CB500 frame suspended directly over my head, and yes I did stand up into it, very very hard.
Anyway, front end and rear wheel off and the frame was manouvered off
https://i43.tinypic.com/2dbv6dx.jpg
As you can see from the slack in the chain (the CB frame is still on the other end) the lifting chains where more than useless
https://i42.tinypic.com/255q59z.jpg
looks like a horrific bike crash

Anyway, then I had to shift the frame elsewhere in the garage, so I popped this on. Good look?
https://i41.tinypic.com/25gewlg.jpg
https://i39.tinypic.com/jf9ftl.jpg
So, frame and engine are seperate entities. Then my girlfriend arrived and pointed out my head was bleeding (from standing into the CB frame) so I went for a shower
https://i40.tinypic.com/nwbhb7.jpg
Heres a little sneak preview of the next update
https://i44.tinypic.com/2vs2rlj.jpg
https://i44.tinypic.com/2z70poo.jpg

[BenR]

Nice bike. I hope the fairings are going back on though?
____________________
Current bikes: suzuki RG125UN wolf. Yamaha MT-07

[Tristan.]

Sold them a while back unfortunatley. Considering a new set. Will have to be able to get them cheap though. Will be a while before it comes to the cosmetics.

[Tristan.]

Oops, just opened this on a slower PC, sorry about the size of the pictures. I'll resize next time.

Anyway, I'm at the pleasent part of a project, where every day stuff gets delivered, here's the more interesting bits
https://i35.photobucket.com/albums/d170/tristanthe/hats/SAM_0043.jpg
Unfortunatley I'm still waiting for a rather important bit before I can make any real progress. So today I just did some aligning of stuff, nothing particularly interesting. First, since I'll be opening it up soon, I gave the engine a good clean
https://i35.photobucket.com/albums/d170/tristanthe/hats/SAM_0044.jpg
Cream cleaner + paraffin in a squirty bottle. Fucking excellent.

Next I popped the FZR400 frame on. Unfortunatly the bit thats missing is the mount thingy for one of the rear engine mounts. As you can see the frame hole aligns with the engine hole, but nothing else
https://i35.photobucket.com/albums/d170/tristanthe/hats/SAM_0046.jpg
Should be getting that sometime next week. Then the real progress can begin.

Anyway Next I had to modify the front tank mount, because of the closer spaced holes and the steeper angle
https://i35.photobucket.com/albums/d170/tristanthe/hats/SAM_0047.jpg
OK, thats boring as fuck, but it took twenty minutes soul destroying dremmeling and angle grinding, so I want to show it off

Now, choices with the tank. If I carry on trying to fit the 600R tank, I'll need to cut the back lip, so it drops down a bit, and make some kind of mount
https://i35.photobucket.com/albums/d170/tristanthe/hats/SAM_0048.jpg
if that flat bit was a bit narrower the whole back end of it would drop by about two inches, which I reckon would make it follow the lines of the frame quite well
https://i35.photobucket.com/albums/d170/tristanthe/hats/SAM_0049.jpg

Unfortunatley, theres fuckall room under the tank
https://i35.photobucket.com/albums/d170/tristanthe/hats/SAM_0051.jpg
thats without carbs, with carbs theres maybe enough room for pod filters, but certainly not an airbox

Anyway, with nothing much to do I did a little mock up for the R6 tail, kindly donated by mattspratt
https://i35.photobucket.com/albums/d170/tristanthe/hats/SAM_0052.jpg
https://i35.photobucket.com/albums/d170/tristanthe/hats/SAM_0053.jpg
yes, I know, it looks pretty horrible. When it all aligns right I'll recide whether to go with it or not, but since the tank needs deciding first, no point.

Anyway. Then I stripped the loom and ancilleries off the 600 frame, to get a bit of a comparison.
https://i35.photobucket.com/albums/d170/tristanthe/hats/SAM_0054.jpg
https://i35.photobucket.com/albums/d170/tristanthe/hats/SAM_0055.jpg
According to my scales, the 400 frame comes in at 10 kilos, the 600 at 20 .

[Billing]

There's a thread on 400greybike in the FZR section about putting a 600 engine in the 400 frame, are you using a 3TJ frame?


Some very useful info on the conversion there mate
____________________
'84 TS50X, '91 TZR125, '89 CBR400RR, '91 VFR400R NC30, '98 R1
"Hey copernicus! Why don't you navigate yourself to the back of the line with your feet and stand there with your shit."
BCF Eastern members map here ---> g.co/maps/2tm8b PM me to be added to it!

[TUG]

Yes that is a 3TJ frame.
____________________
Haz ER-5, innit!

[Tristan.]

Yeah, I'm a member of 400greybike, a helpful forum, in fact the two times I've made posts there I've had PMs with people offering to sell me stuff at sub ebay/breaker prices. And it is a 3TJ frame. The older 3EN (not sure about the 1WG/2TK) frames also take the 600 engine, but with no provision for the top mount (should be ok though, as the 3HE 600 engine was in a similar frame as them, with no top mount, and the engines weigh practically the same)

Hmm, I can recite pretty much every FZR model code, I've put a quite worrying amount of research into this.

What was your 400 Tug? I think it had twin round lights, so 3EN1/2 [edit, nevermind, just saw your sig]

[TUG]

3EN1 i miss it, its still down the side of my house rotting away, i need to phone the scrap men on tuesday to arrange picking it up so i can get rid of it.
____________________
Haz ER-5, innit!

[Tristan.]

Fancy selling the fuel tank? I'm presuming the cover is fucked though

[TUG]

lol you can have the whole bike if you could be arsed picking it up?
The cover will prolly be weathered to fuck but i have a 400 set in the loft with a tank thats in good nick, but i assume your going to respray it?
____________________
Haz ER-5, innit!

[Tristan.]

Yeah full respray, that wont be for ages though. I'm just thinking of ways round the tank/airbox problem. A guys sending me a 3TJ tank, which is apparently a normal metal one, and I have the 4JH one obviously, but if I could get hold of the old style fuel cell and dummy cover one hopefully I could salvage some kind of system from the three. Your a bit far for pickup (though how far are you from Doncaster? My mums boyfriend might be interested)

I'd happily give you a tenner plus postage for the tank, airbox and whatever cover you have, plus any relevant affixing bits and bobs which might present a solution

[TUG]

Doncaster is an 1hr 38mins away according to google. I don't know whats of use on it, i'll take a look this week end and get some pics, the old tank might be of use considering you want to paint and mod it, the air box you'll love even has a new K&N haha.
____________________
Haz ER-5, innit!

[Raf]

Looks promising. If you need any tools i have the air compressor with a bunch of pneumatic air tools not being used. Also got a bottle jack not being used, might come in handy for when you attempt to get that engine back in.

P.S *Do not sandblast the engine*
____________________
CBR1100xx - BMW K1100 - BMW K100 - Triumph Sprint ST 955i - Suzuki GSX-R 600 - Suzuki DR 350 - Yamaha XV 750 - Honda CBR 600 FM - Yamaha XT 600 - Yamaha Rs 200 - Honda NSR 125

[Tristan.]

Cheers for that, may take you up if I want to sandblast anything. I heard you got rid of the CBR? If so what you riding now?

Today started nicely, with the arrival of some sexy presents:
https://i35.photobucket.com/albums/d170/tristanthe/SAM_0056.jpg
Unfortunatley, the ebay ad was kind to them
https://i35.photobucket.com/albums/d170/tristanthe/SAM_0058.jpg
Though it isn't rough to the touch, so it should hopefully clean up ok. I decided to strip them down, then realised my 32mil socket was at Matts. No problem:
https://i35.photobucket.com/albums/d170/tristanthe/SAM_0059.jpg
clip on handily from an R1, from when I bought the brakes a while back. Anyway, then to get the allen bolt out the bottom



Ugh, I dont know if you've noticed from the backgrounds of the pictures, but I am by no means a tidy person. I know for a fact there are 5 10mm allen keys in my garage, two from socket sets, the T bar one I butchered the other day and two from sets. It took me over 2 hours tidying/searching till I found one. 20 seconds of lidl grindering took the bent end off, so I could pop it in a 10mill socket. Then the fucker rounded. Fortunatley the key rounded more than the bolt head, but I'm very wary about doing it by hand again, as fuck knows how I'll get it out if it properly rounds. Fortunatletey a TX55 fits in there beautifully now. So I need a big vice, and some leather jaws before I try again.

Anyway that, plus the condition of the stanchions fucked me right off so I packed it in for the day. I may go out later to modify the fork bottoms to take my bluespots:
https://i35.photobucket.com/albums/d170/tristanthe/SAM_0060.jpg

[Raf]

Np, also if you need to paint anything it works out far cheaper then using cans.

I still have the CBR and the XV but they should be selling soon, i picked up a 97 gsxr 600 yesterday. Just needs electrics sorting which i pretty much finished today. Taking it in for MOT tomorrow.
____________________
CBR1100xx - BMW K1100 - BMW K100 - Triumph Sprint ST 955i - Suzuki GSX-R 600 - Suzuki DR 350 - Yamaha XV 750 - Honda CBR 600 FM - Yamaha XT 600 - Yamaha Rs 200 - Honda NSR 125

[tutton]

Liking the project,
my fzr with your fairings is long gone now
____________________
Past: '05 Peugeot XPS '99 Aprillia RS125 '94 FZR600R
Current: '02 ZX636 A1P '51 CCM R30

[richbike]

Ikea ratchet straps are good for hanging bikes from the garage joists.

Amongst other things..