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Fzr400 Engine Swap Questions

Posted: Wed Mar 12, 2014 9:44 am
by Polski1
I have tried searching but I'm still a tad confused
Looking to put a 600 into my 400 frame

It's an 87' which makes it a 1wg I think?
So which fzr600 engine fits straight in?
Also does the Thundercat engine fit in these frames?

Also I've red with a 600 engine fitted the airbox needs modified, How do these engines run with pods? Or trumpets? Obviously with the carbs played with
Which tank is best to go for? Planning on running an r6 tail I think

Maybe I've been searching in the wrong place so I apologise if these questions have be answered elsewhere

Re: Fzr400 Engine Swap Questions

Posted: Wed Mar 12, 2014 12:46 pm
by Evilchicken0
The easiest 600 engine is a 3HE they made them up to 93 I think, after that there was the 4JH Foxeye and then the 4TV Thundercat.

The 3HE is basicly a long stroke version of the 400 1WG, the 600's have a steel frame and swingarm but the rest of it is ... almost similar, so the 600 will bolt straight into your frame. You'll need the downpipes (they're slightly longer). You can use the 400's CDI but the 600 units are fairly cheap, and if you do use find one they won't have the Jap top speed restriction on and you could swap to 600 clocks (they'd be MPH then). The airboxes are the same but the 600 engine is taller - so you might find it easier to space the tank shroud and lift the (proper) fuel tank a bit. Don't run pods they won't suit CV carbs, there is a K+N airfilter that will fit, it doesn't increase airflow but you will be able to wash it. The 400 chain is lighter (428 I think) maybe use it until it dies then replace it with a 520 conversion.

If you bike is a 87 model it should have two headlights with (false) air intakes above, the swingarm will be braced ... this is a FZR400R 3EN1 Exup model. It also has 38mm dia forks and 285mm disks.

Don't bother with the R6 tail unit they need a lot of work and usually look shite.

Re: Fzr400 Engine Swap Questions

Posted: Wed Mar 12, 2014 3:45 pm
by Polski1
Major helpful reply! Pretty much answered all my questions right there
So the Thundercat engines straight fit too? I seen somewhere wiring is an issue with these but I've looked at full wiring looms and there not exactly bank breaking

I'm working with basically nothing so whatever engine I get I will be getting all electrics/exhaust/carbs etc too suit

Yamaha ran my frame number through there system came back as a FZR400R 1987 Model Type Code – 2TK0 unsure what this actually means? I was told by last owner it was an sp version but I've actually not much clue with these
This Is what I have as a starting base so if anyone can tell me what it is would be much help

Image

Just wanting to build a cheapish toy for weekend use, Probably gonna have a streetfighter look to it as full fairings is extra cash

Was gonna run a r6 tail as I've seen them come up cheapish, What would you recommend?

Re: Fzr400 Engine Swap Questions

Posted: Wed Mar 12, 2014 4:36 pm
by Evilchicken0
That's a 2tk - it was the SP which was between the Genesis and the 3en models, it had lots of extra bits that became standard on the 3en.
Um .. sooo is there any more of it or do you just have a rolling frame ?
If that's all there is then I'd recommend buying a reasonable 600 3he and building and basically swapping the frame. The 3he uses framerails to mount the engine the later foxeye and thundercat use the engine as a stessed member. The 3he cases are common to your 400 frame so you wont have to mod much to get it in, the sprockets will line too.

The 600 bodywork will drop straight onto the 400 as long you use the corresponding subframes. These bikes have square tail sections ... The R6 has a wide flat section tail ... they just won't work visually with the bike.

Re: Fzr400 Engine Swap Questions

Posted: Wed Mar 12, 2014 4:52 pm
by DonTZ125
The thing to be careful with when using the 400 TCI box in a 4/600 build is the higher redline of the smaller engine. Racers used to blow up their engines doing this; I don't know if a street build would have the correct jetting etc to rev the keepers out of the springs. Use the 600 box if possible. If you want to use the 400 box and bump the redline a little, I make a plug-in rev limiter to keep the valves in the head and out of the cylinders.

I haven't looked at a sprocket catalogue in a while, but I do NOT believe the 400 and 600 front sprockets are interchangeable, and there I've never seen a 428 for the 600. Be prepared to use a 520 chain and sprockets.

The 4JH and 4TV 600 crank patterns and TCI boxes are completely incompatible with the 400 and 3HE 600; if you use a 4JH or 4TV engine, you need a 4JH or 4TV TCI. They are basically interchangeable; the 4TV box expects the throttle sensor from the carbs. You're looking at a harness transplant (not much of an issue since you're starting with a bare frame) or I can make you a plug-in adaptor.

Re: Fzr400 Engine Swap Questions

Posted: Wed Mar 12, 2014 6:03 pm
by Polski1
Some really useful information here!
So a 3he engine will be the best one to get for ease of fitting? Along with loom/cdi/carbs/exhaust etc
I doubt ill beable to find a 600 local but 1 may pop up

Yeh this is all I have reason being I want to stick a 600 in it, I'd be aswell since it needs an engine fitted anyways

I'm not overly fussed on what fairing gets put on really as it's it's something I wanna put together cheapish to have some fun on, The roller cost me nothing so with the price of an engine/loom/exhaust etc plus will probably upgrade the shock and forks plus little pieces here and there the bike won't owe me that much
I actually have an old school looking race tail, Has a big square hump on it might see how that looks on it once I source a tank

Don ill give you a shout if I need a rev limiter off you, Chances are ill run a 600 loom/TCI so won't need one

I've also seen elsewhere r6 headers fit onto fzr600s but they didn't state what engine, anyone know?
Also are there any other carb options for the 3he engine?
Think this is the last question, Are there any performance parts worth putting onto a 3he?

This forum seems like a pretty good one!

Re: Fzr400 Engine Swap Questions

Posted: Wed Mar 12, 2014 6:11 pm
by DonTZ125
R6 headers can be MODIFIED to fit the 3HE, and I would presume the 4JH and 4TV. ThatKid sells modified and powder-coated headers, ready to bolt up. Shipping to you side of the pond might get ugly ...

Performance parts - degree your cams, then do ReelRazor's Poor Man's 5 degree timing advancer mod. If I ever get my thumb out and get my programmable ignition into production, buy that! :deal:

Re: Fzr400 Engine Swap Questions

Posted: Wed Mar 12, 2014 6:20 pm
by Polski1
Yeh it' would probably work out cheaper getting them modified here, I'm unsure what it consists of to get them to fit but I could probably get it done on the cheap, Few of my mates are welders/fabricators, Will need to search up see if it's a worthwhile mod or not

I'll need to look up then 2 mods you mentioned too
Your programmable ignition sounds like it would be interesting, What does it involve? Not all that clued up with the electronics side of things ha, I know the basics but go into that kinda stuff and it confuses me slightly

Re: Fzr400 Engine Swap Questions

Posted: Wed Mar 12, 2014 6:22 pm
by thatkid
Also, if you decide to go with a thundercat engine I have a TCI and harness I can ship over the pond for a "reasonable" amount. Might even be able to get an R6 rear shock in same box depending on how good that current shock is.

As for the r6 header...Definitely worth it if you don't have an aftermarket exhaust. The r6 header runs a 4-2-1 design which gives a much better power curve. It also allows the use of almost any slip-on out there.

Re: Fzr400 Engine Swap Questions

Posted: Wed Mar 12, 2014 6:51 pm
by Polski1
Gonna need to have more of a think about it, I'd rather go with a Thundercat engine as I can pick one up a lot easier over the 3he but it seems like abit more work to get into the 1wg frame

Drop me a pm though, Also wouldn't mind asking you abit more about the r6 header modifications

Re: Fzr400 Engine Swap Questions

Posted: Wed Mar 12, 2014 6:56 pm
by DonTZ125
Look around for how-to's for the side mount plates to get the TCat engine in. I think there's one over on FZRArchive.

Re: Fzr400 Engine Swap Questions

Posted: Thu Mar 13, 2014 5:33 am
by willandrip
This is what your bike would have originally looked like;
Image

This is what can be done with a little work and a YZF750 lump;
Image

Just a couple of ideas for you,

Do not chop up the ally subframe to fit a r6 tail;they sell for good money and you could use that to buy the earlier 1WG Genesis
frame that bolts straight on with money left over for extra bits.
Your stanchions look in poor shape ( the top nut adjusters have already been swapped out) but 3EN1(400) or 3HE 600 ( much cheaper)
tubes will fit.
The tank cover is gone but the earlier Genesis or 3HE could be made to fit the frame.The front mount is different
The clip ons normally go above the top yoke;if you drop the forks down flush with the yoke it will ride like a chopper ! :yuck:
Most Genesis and a lot of 3HE stuff bolts on to these which is good as the bits are the cheapest.
You might find a crashed 600 is a lot cheaper to get than individual bits for the swap.
Def. get the 600 TCI.
If the pic shows all you have; a great deal of time and money will go on the little missing bits.

If you need owt; shout up, I have a few reference pics.
Image

Your just a little late;
last week a 3HE good known engine/carbs/airbox/harness and electrics + fixings went for £75 collected in Edinburgh.

Re: Fzr400 Engine Swap Questions

Posted: Thu Mar 13, 2014 5:56 am
by willandrip
You mentioned suspension upgrades; these are easy and cheap,giving better rubber choice. (17" rear opposed to 18" your stuck with.)

Trx 850 swinger + 4JH rear wheel in a Genesis frame,

Image

4JH front end in a Genesis.

Image

Re: Fzr400 Engine Swap Questions

Posted: Thu Mar 13, 2014 6:00 am
by Polski1
That's a proper nice bike you got there!
Any ideas welcome as I said I'm new to these and any ideas I've put up are ones I've only thought about the past couple of days

Is there much differance between the yzf600 and 750?
Everything in the picture is all I have, The forks ain't too bad it's mostly surface rust, I've cleaned up worse before but I have been looking at swapping them out for some usds (Been looking at guides and stuff but haven't put any thought into that yet)
The tail swap might not happen I've just seen a few with yzf tanks and r6 tails and I quite like the look of a few of them
Kinda money the subframes go for? I can get a custom one made for little money so may end up making my own if I fit a r6 tail

That engine and bits would have been perfect! Was down that way last week aswell, Was it on this forum?

Re: Fzr400 Engine Swap Questions

Posted: Thu Mar 13, 2014 6:15 am
by willandrip
The 750 requires ally welding/fab skills ; the 600 much less if any.
I have only seen 2 Tk subframes in 3 years; a bidding war started both times..

Genesis;
http://www.ebay.co.uk/itm/YAMAHA-FZR-40 ... 528wt_1012
The engine was a bay job; I nearly went for it.