My FZR600R Foxeye Restoration

[dougs]

Gutted for you Doug.
I would'nt have believed a smaller spocket could have done that without seeing it .

Thanks, the sprocket was not at fault it was an incorrect chain adjuster which failed, from a mechanical point of view the design is not great for high loads and does not fail safe as would happen with the new type designs I will be making improvements watch this space

[dougs]

The original chain adjusters the broken one is from a 3he model


The new ones I made from steel damn things arent gonna break again!!!

[dougs]

rebuild is nearly complete for all the help and advice i have had it has all helped to put it all back together
some before and after shots






nearly done

[Yamster]

Looking good Doug .

[rotortech]

Doug,

I just read this entire thread.

I love your bike. Your workmanship is a real gift.

Sorry to see the chain tensioner failure, ouch! Everything looks good now. And I wasn't at all surprised that the rear suspension bearings were trashed. Typical with older bikes in my experience.

[rsaddo]

nice build bud unlucky on the adjuster quick question did you manage to get hold of a new bearing and seals for your rear linkage buggered if i can find one for my bike?

[dougs]

yes i got a new bearing sleeve and roller bearings off ebay (patterned parts) the seals were fine but don't cost much from yam anyway think the bearing kit cost just under £50 so pretty reasonable
edit' if you are talking about the linkage for the shocker then i could get one but only from yamaha and they are mental price at £180+ so i gout a whole triarm linkage off ebay for £15 bit of a gamble but it turned out it was in good condition

[yamaha_george]

Doug,
The failure of the chain adjuster of that design is NOT new and is in fact quite common. I bought aFZR swinger and the adjusters on that were bent inwards fracturing was waiting to happen, replaced mine with alloy slab milled out to suit

so far at least they have not buckled <BG>

[dougs]

Thanks YG mine are now milled from mild steel see photo above I like the side plates you have think I will add that mod too should spread the load better. Have you swapped the rear spindle for solid?

[rsaddo]

well i cleaned my spehrical bearing pressed in the outer case a small amount to get rid of the sloppiness regreased refitted the seals job done 180 squid my arse as for my chain adjusters think im gonna have to make some tomorrow 51t rear sprocket aint gonna be to kind on the originals

[dougs]

well i cleaned my spehrical bearing pressed in the outer case a small amount to get rid of the sloppiness regreased refitted the seals job done 180 squid my arse as for my chain adjusters think im gonna have to make some tomorrow 51t rear sprocket aint gonna be to kind on the originals

That's great news, word of warning tho running a low ratio check check and check again all bolts are tight and nothings worn , wish I had checked more

[rsaddo]

well i cleaned my spehrical bearing pressed in the outer case a small amount to get rid of the sloppiness regreased refitted the seals job done 180 squid my arse as for my chain adjusters think im gonna have to make some tomorrow 51t rear sprocket aint gonna be to kind on the originals

That's great news, word of warning tho running a low ratio check check and check again all bolts are tight and nothings worn , wish I had checked more

now ive seen this thread and read a bit of the same elsewhere i wont be taking any chances bud and one more cool mod is always a good thing

[yamaha_george]

Thanks YG mine are now milled from mild steel see photo above I like the side plates you have think I will add that mod too should spread the load better. Have you swapped the rear spindle for solid?

D,
the bike that is for is from the early 1980's see:-

http://www.saltmine.org.uk/kgb/yellowperil.html

so the axle was solid when I get a machine shop to use again I might either bore the axle or go for a hollow fatter axle entirely

[dougs]

wow love the attention to detail even bushing the aluminum on the shock mounts that's pretty dam cool. i like the bobbins as well that's def a mod i will have to do at some point

[yamaha_george]

wow love the attention to detail even bushing the aluminum on the shock mounts that's pretty dam cool. i like the bobbins as well that's def a mod i will have to do at some point

Doug,
yup the bobbins are the best mod for the frame to be sure , if you like that detail take a look at :-

http://www.saltmine.org.uk/kgb/paddockstands.html

just some old scrap I had lying around from a lab table job a mate was doing "waste not want not" I reckon that is probably the most expensive paddock stand ever if I ever had to make another one LoL