fzr400 3en1 project

[TUG]

this is how it started out.
https://w2.bikepics.com/pics/2007/05/09/bikepics-893095-full.jpg

i've done alot of work on it, so far i've fixed the rear wheel bearings, fixed rear caliper, new tyres, new clutch, new chain and sprockets, new clutch cable, new clutch lever and bracket, 2 new exhausts, custom link pipe, had the downpipes welded where they had rotten through.

things to do, r6 shock on, fork seals, r6 front brakes to put on and maybe a new rear tyre.


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Haz ER-5, innit!

[TUG]

over the past few month i've done not so much as i'd like, i've put exhaust wrap where its leaking at the joints, mot is due and the R6 shock wont fit, so i've got a working rear shock off a fzr 4, and ive got to fix the seals on the forks for the mot, also got some fairings (fingers crossed) coming.
watch this space, cant wait till the before and after pics
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Haz ER-5, innit!

[TUG]

bikes almost done now, coming to the final hurdle, the gearbox, i won those plastics, and for £185 there in great condition.
https://w2.bikepics.com/pics/2007/09/19/bikepics-1028997-full.jpg
https://w2.bikepics.com/pics/2007/09/19/bikepics-1028999-full.jpg
https://w2.bikepics.com/pics/2007/09/19/bikepics-1029000-full.jpg
https://w2.bikepics.com/pics/2007/09/19/bikepics-1029002-full.jpg
last 2 havent been washed so look shite, looks like the downpipes have melted a bit of the bottom
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Haz ER-5, innit!

[Jenks]

that meltings very weird! although he could have had different headers on his bike, have you lined it up?? to see if yours do?
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1978 MZ TS 250 1 Supa 5
1992 yamaha fzr1000 exup
1998 aprilia af1 sintesi

[TUG]

yep its on the far right tube, guys over at fzr archives said its normal and replacing with fibreglass ones stop it, but they said might of been caused by fzr600 pipes on as they are very similar. but all in all think i've found a good set seing as they are 19 nearly 20 yrs old.
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Haz ER-5, innit!

[TUG]

been playing with the idea of swaping the lights to LED's recently and xenon headlights to get cagers to see me coming. also been polishing stuff, its almost like a disorder!
https://w3.bikepics.com/pics/2007/10/05/bikepics-1046174-full.jpg
that was my first attempt, really shitty tbh.
https://w3.bikepics.com/pics/2007/10/05/bikepics-1046173-full.jpg
thats how my peg started out.
https://w3.bikepics.com/pics/2007/10/05/bikepics-1046172-full.jpg
what you think? better?
https://w3.bikepics.com/pics/2007/10/05/bikepics-1046169-full.jpg
took me about 3-4 hours, theres something wrong with the metal its corroded deep into it or something.
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Haz ER-5, innit!

[craigs23]

Looking good, you may need to go a little coarser with whatever you're polishing with to remove the worse of the corrosion, then work up the grades getting finer and finer. Takes patience, but a mirror finish is attainable.

Personally, I prefer a brushed ally look. It looks more factory, is easier to get, and isn't ruined when a light dusting of laquer's applied.

One problem though - and it depends how deep your 'disorder' goes, is that you clean one part up to a good standard, and then notice everything on the bike needs doing.

Good work so far.

[alun111]

a good start, althought a finishing touch would be to get some nice sparkly stainless allen bolts for the footpeg hangers etc.. Althought those hangers are looking good, the shitty allen bolts let them down.

[TUG]

yes am working on stainless steel stuff atm, i want to put my new fairing on with some nice stainless bolts then get some for the pegs and other parts, i know what you mean craig, its hard to keep on top of, because all that dirt is from fling off the chain, i really pisses me off when i spend 3 hours washing it and then lube the chain up go to my gf's and my kinda white rim is black again.
i need to get my rims painted soon, but i dunno if i want them white or red to match my new fairing.
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Haz ER-5, innit!

[TUG]

this is a more upto date pic of the FZR
https://w3.bikepics.com/pics/2007/10/05/bikepics-1046204-full.jpg
sorry about it being dark but it helps hide that awful paint work that someone DIY'ed. need to put my new ones on ASAP.
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Haz ER-5, innit!

[alun111]

[McGee]

[TUG]

hey mcgee i'm gunna get a posing pic for you soon i know and there white i'm gettin a CG125 hopefully soon so all should be good. if i get the CG also white (do i have a thing for white and red???) will be great to put back on the road and fix my FZR's gearbox then sort out some stainless steel nuts and bolts, get all the LED's, xenon lights, jack up kit, at some point i need to put my R6 calipers and MC on and get rid of those horrible pink foot pegs with maybe black or chrome ones.
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Haz ER-5, innit!

[McGee]

Awesome.

Will look ace
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◙◙► K6 GSXR 600 ◄◙◙◙◙► K5 GSXR 1000 ◄◙◙◙◙► K5 GSXR 600 ◄◙◙◙◙► 96 RF600r ◄◙◙
◄◙◙◙◙◙◙◙◙◙◙◙◙◙◙◙◙◙◙◙◙◙◙◙►◄◙◙◙◙◙◙◙◙◙◙◙◙◙◙◙◙◙◙◙◙◙◙◙►◄◙◙◙◙◙◙◙◙◙◙◙◙◙◙◙◙◙◙◙◙◙◙◙►
Its pronounced Jixxer!

[Whosthedaddy]

The dog bone jack ups are a doddle to fit and mine cost me less than £25 or there abouts. If you are going to do it, it is a lot easier with the wheel removed. Took me 30 minutes or so with it in place!
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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

[TUG]

do they make a big difference? will it make it look higer at the tail or just raise it by 10mm or so? cos i want the look as well as the lift, not just the lift.
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Haz ER-5, innit!

[Whosthedaddy]

The shorter the bones, the higher the ass will be. Without a correct tail jack up (as on some hard core streetfighters), the bones will only lift the rear section away from the line of the rear wheel and push down on the front. This will make the bike turn into corners a little better but also makes the rear a little more skittish as the weight distribution has changed, or something to that effect.
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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

[TUG]

Not really much to post about the bike as far as project goes, the R6 tail swap was a fail as i fell in love with the 80's style, the R6 shock wont fit either so if anyone needs a fully adjustable R6 shock off a 06 model then PM me. I need to put LED's in the clocks soon as its starting to piss me off not being able to see temp and revs.

I fitted a new airfilter too, dam its good bike feels like a bike not a flooded tank. Still needs:-
NEW Fairings fitted in summer,
Full LED bulb swap,
Jack up kit,
New paint on the rims,
Frame painted,
HID kit,
Clear rear brake Lense,
Renthal Grips,
R6 brakes fitted,
BT90's Fitted,
Tyre pen,
Oh and a Race engine swap,
Fix the stock motor gearbox and carbs,
Thats it really, not that much but will take a while till complete and am sure more problems will develop.
Bike looks like this atm,
https://w3.bikepics.com/pics/2008%5C01%5C09%5Cbikepics-1142674-800.jpg
Feelin sorry for itself.
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Haz ER-5, innit!

[Whosthedaddy]

The R6 shock would never have fit unless you changed the swingarm. Even on the 600 it's a job unless its a later year and model with a much larger hole.

Not even sure if the R6 calipers would be a straight swap due to the hole positions on the stanchions.
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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

[TUG]

[Kickstart]

[TUG]

[SoND]

[TUG]

Ok heres the deal, FZR is how you say... Fucked is the only word, So its due off the road for a long time. Cant sell it, wont get anything for it as mint examples sell for £700...
So, the CG cafe racer will have to just fucking wait as the 20 year old fzr has finally had enought and doesnt want to carry on.
Needs,
Setting on fire,
Bearings and seals all around,
Race shock,
Engine stripped and rebuild to new cond,
Frame powder coated black,
Rims powdered white with red rim tape,
Loom out and cleaning fixing up,
Exup bushes and valve fitting,
Fork internals,
Carb rebuild,

Thats to get it on the road again. So much for summer eh.
This thread should be in show and tell but ow well.
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Haz ER-5, innit!

[Deano]

break it and sell my your clip ons
seriously though if you have a spare set give me a shout, cheers.