My interpretation of a FZR - *FINISHED*

[cad600]

Well, during the last month I've been busy sorting things out for the 660 build and finding the parts I need to complete it. I've also been dismantling and cleaning the parts I do have. This allows me to look over each part and see if it needs replacing. I won't boar everyone with each before and after picture, but here are the parts that I've cleaned so far.

First up is the water pump. I also installed new seals for it.


Pistons and Conrods. New rings, pins, conrod bolts, and rod bearings will be installed.


Cleaned the stator rotor.



Oil pan


Shift linkage


Here is the transmission counter shaft and gears.


The entire transmission was cleaned and inspected.


Clutch basket and parts.


Aftermarket stator cover for a FZR.



Top half of the engine case - before: New crank bearings will be installed.




After




Lower half engine case - before:




After




And I finally got the Ignitech computer today.


I'm going to start putting the lower half together this week.

[sweekster]

Ignitech huh? I hear those are fully adjustable. Nice. Glad to see progress is still going with this one.

[Genesis]

It is looking good. I really should do that to my bike before I move to New Zealand, MAF gets really sticky if the Bike is dirty.

[cad600]

Thanks for the compliments guys. I can't wait to get this thing on the road. I've been busy trying to locate the remaining parts I need to do this build, and I think I finally have everything on it's way. Only piece of the puzzle I'm missing is a jet kit but I want to wait to see what it needs first as far as that goes. I was able to track down a new NRC starter cover and a new full Barnett clutch kit for half the cost. Falicon adjustable cam sprockets factory direct (got to love not having to go through a dealer) and the rest of the seals and gaskets from Yamaha. The last piece of the build is coming from Dru86 and is a 3mm base gasket. Hopefully, it won't take too long to get here.

Mark is going to give me a hand putting this together. We are going to start this coming up Thursday. Pictures will document everything.

[cad600]

Well, I hit a snag with the engine build. I starting putting it all together and was things were going well until..... I snapped off the bolt for the shift dent arm. My efforts to fix the problem went horribly wrong. I have since sent the engine case to a machine shop to have the bolt hole center bored, plugged, and re-tapped. Mean while I was hopping that Jay (match417) would have the motor he got a hold of stripped so I could have the engine cases. Well, I want to ride so while I'm waiting on everything to get fixed or mailed to me I decided to buy an engine that needed nothing.



This is a YZF600 engine with less than 5,000 miles on it. I was able to get the engine with the carbs, wire harness, and computer. Mark (95FZR600) went with me to get it today. had to drive 3 hours each way but I got the engine at a hell of a price. I hope to have it in the frame by Monday. The only snag I'm expecting to run into will be the ram air set up. I'm not sure how I will get that to work.

More to follow.

[megaloxana]

hell yeah Rob, thats what I'm talking about. Good luck with this motor.

[sweekster]

I have a question for you Rob...I happen to have an airbox for a foxeye YZF600 (missing the boots) that I have no use for-would you be able to use it? Congrats on the motor and good luck with the 660. I'm looking forward to seeing both in action.

[cad600]

Got to work for about an hour on the bike today.

One engine out and the other one is ready to go in.



I hope to be able to put the other one in tomorrow.

[thatkid]

That is a nice bike you've got going on. Every time I see it I want a single sided swinger. Good luck with the motor.

[sweekster]

Really impressive Rob. Looking back on all the work you have put into your bike. All I can say is impressive. Keep it up because it's getting there and you'll be riding quite soon.

[cad600]

Thanks for the encouragement guys. The items to be completed are slowly dwindling.

Out with the old and In with the newer. Got the YZF engine into the frame today.



Last things to do are check the sprocket alignment, get the wiring installed, put the carbs on, and see if it will crank up. I've already started looking at the sprockets. They are pretty close, but I'm going to through some different sprockets on there to see if I can get it closer. I've got a couple of options for the wiring. I got the entire system with the engine so I can use that or I can run the FZR wire harness that is in there now and plug the Ignitech computer up to it. I got the company to send me the program for the engine and the only difference for engine wiring would be the thermostat, which I've already made an extension cable for. So we'll see how much I can get done tomorrow.

I've still got to figure out the ram air system. There are a couple of options, but I'm not familiar with them so I need to do some more research.

[sweekster]

It's almost there. Almost there.

[cad600]

Hell ya Billy, great idea for a bike. Glad we both thought of it.

Here are the pictures just for you Mark -

Got a standard YZF Vortex 520 sprocket installed.


With the shaved rear sprocket carrier, the chain alignment is dead on.


I was able to get the carbs installed today. Also hooked up the wiring to the engine. I'm going to try to use the FZR wire harness with the two custom attachments plugged into the Ignitech computer. The thermostat is in a different spot and I need to add a wire connector for the throttle position sensor (yellow and blue wires hanging over the side).


This is a picture of the nut that holds the rear axle in place. It is a huge 42mm nut that takes 142lbs ft of torque. You can see that the design leaves a little to be desired. I'm not saying that Honda didn't know what they were doing, but it has never sat well with me. Especially after the nut came loose on me going down the road - my fault entirely, but still.


To compansate for this, I had Modking make me a new nut that wouldn't have this problem. It is still a large 42mm nut, but it is full threaded and cut so I can put a cotter pin through the axle.


Tomorrow will be putting the FZR cables onto the carbs and finalizing the wiring. If I can get the computer programed, I might try to fire it up.

[cad600]

Lucky SOB...........

But remember, I've bee working on this for 2 full years now. You've been working on yours for only a few months.

[cad600]

A little more done. I was able to get the motor to fire up. I'm in the process now of cleaning the carbs on an extra set I have. But I'm also waiting on a set of carbs from a '95/'96 model so I can ditch the ram air system. I'll loose the TSP but it will be a lot simpler in the end.

Today I was able to get the rear end apart, drill the axle, and put it back together. I place the new nut and cotter pin in there some what loosely for now. Modkking made the nut for me. Only thing I don't like about the way I designed this is that I will have to remove the pin to use the single arm stand I have.


I got annoyed with the KOSO gauges I had bought so I've decided to switch to the Vapor gauge by Trail Tech. Wiring was fairly straight forward.


I'm also swapping the controls to YZF spec to make things simple. Here is the Light control which also operates the choke.


Here is the R6 Start switch and the YZF throttle tube/cables.


Here is the Ignitech computer all hooked up to the main wire harness. The extra lead coming out of it (with the red cap) is the data connection port so you can program it.


Enjoy.