95 FZR 600 build

[cntryboy85]

so it has been a while since i posted about the bike. i have started the 660 build. as of right now the engine is half way tore apart. i have started accumulating all the parts that i believe i need and a few that i want. but still have a little ways to go. i get to go home in 2 weeks and am going to be dropping the lower end and the cylinders off at the shop to have them honed and have the rods fitted for the new wrist pins. my buddy started working 2 jobs so is kinda in dead lock he works from 6 am until about 10pm 6 days a week so he doesn't have a lot of time and what time he has is now spent trying to get his 83 shovel head into running condition. also part of the problem is that he has all the bolts out of the oil pan but it just doesn't want to come off. he is afraid to put too much pressure on it for fear of damaging the case, so going to leave that to the pro and proabably give it a good bath so that as it goes back together can give it a shot of high temp paint and make it look a little better. but here is a list of what i have gotten so far..picked up cylinders, head, cam chain tensioner and pistons from ebay for a 2003 YZF 600 paid $90. this is what i have ordered from PARTZILLA.COM
clutch kit: $70.33
cam chain tensioner gasket:$2.54
head gasket: $40.08
piston rings : $127.60 for all 4 sets
valve cover gasket : $23.52
wrist pin clips $14.97
cam chain $24.35
complete engine gasket kit: $164.15...any gaskets i dont use i will offer on here for the price of shipping
factory pro stage 3 jet kit: $113.77
oil seal: $6.09
all together so far i have put out $676.39. going to be using either K&N dual carb filters or individual pods i am not sure yet and picking up a Yoshimira SS2R slip on. if i cant make the under tail that i have for a 06 R6 work. would love to see an under tail on it. not to mention i got it for dirt cheap and already have it not needing to spend another 250 on a muffler. also once i get the engine up and running going to see how it does with the factor set up sprockets and go from there for the ones that i want to set it with. eventually going to pick up the R6 shock and maybe YZF swing arm but that isn't for a while. been getting a lot of good advice on here and love to keep it coming. will post pictures when i get home and get a chance to take some good ones.

[thatkid]

The exhaust will not work. If you get it to work, you have to snake the pipe behind the rearset, around the swingarm, up and under the tail. It's not a good look. Go for a high mount or a shorty. Unless you have a swingarm designed for an undertail it always looks forced.

[cntryboy85]

thanks for the advice. i was hoping it would work. i have always thought that a bike with under tail mount always looked cleaner than side mounts but if it is going to be that difficult then it isnt worth the extra time and effort when i can just get the slip on and put it on. not to mention the SS2R sounds amazing. so i guess that part is settled then. so if you know any one that needs an exhaust all polished stainless from header to muffler, just needs gaskets let me know and i will let it go to clear up some extra space in storage.

[cntryboy85]

ok so update. thanks to the typhoon that hit PI i will not be going home next weekend as originally planned. i am not sure when i will be able to get home. i hope it is soon. i need a ride and need to get the bike to fire up. it has been a year since she has seen roads on her own.

[cntryboy85]

so it is starting to come together. just ordered 1998 YZF 600 header with D&D muffler from ebay. it will be at my buddies house on the 5th of Dec. i am hoping to be home on the 14th to be able to start work on it (wife permitting) and hope to have its first start as a 660 before i leave on the 28th. would be so nice. but its a long shot. would be happy to just get it all pulled apart and get a good bath and start the rebuild but it all depends on what the wife has planned for my first time home in almost a year and weather. but will post pics when i get home of all the parts and progress.

[cntryboy85]

ordered my new K&N air filters last night. went with dual air filters. 1 for 2 carbs. hope they work out. all that is left now is to get it pulled apart, cleaned up, machined and built. while its down i am going to be pulling the calipers and heal guards off and those along with the yzf header valve cover and what ever part i can think of is going to go be either powder coated or ceramic coated thinking just powder for the brakes and heal guards and ceramic for the header to keep some of the heat down.

[DonTZ125]

Do some searching here for pod filters and stand-off PVC. You'll find them MUCH easier to tune.

[cntryboy85]

i think i found the post you were talking about for setting up jetting on the carbs. i know it will be a little more difficult to set them up but i have heard bikes with pods and like the way they sound better than ones with air boxes still on. also hearing they give a little more power under more aggressive throttle. how true that is i am not sure. but thanks for the heads up. i will post more when i get home and get some pix and more progress.

[cntryboy85]

back at home. got a lot of the parts cleaned up and taking pictures along the way. bad point right now possibly have to buy a new piston and wrist pin. one of them are stuck together and cant get them apart so that isnt good. about to try get get the bottom end pulled apart but i have been told there is 2 bolts that you have to take out from the inside of the case but havent been about to find them yet been cleaning up what is already off and going to paint the covers while i have some time and they off of the bike. but hope to have it all taken apart and ready to go back together this weekend for maybe a test fire before i go back to japan. b ut will post more when i have done a little more.

[cntryboy85]

Dropping rods and pins off at the machine shop today going to be able to pick them up either later today or early tomorrow. Have everythingg with the rcxception of the engine case cleaned up and ready goto. Lots of pictures going to come up soon.

[cntryboy85]

didnt get the rods and pins to the machine shop. the shop that i called and told them what i had and what i needed told me over the phone that they could do what i wanted. however when i got there and put them on the counter and said "i need this to fit this" the guy looks at me and says we cant do that. So i went on the hunt to find any one that could do it. the one shop that i found that could do it after a day and a half of calling and driving around told me that "this is a custom job. that we cant guarantee that the rods will hold up. and that best case it is going to cost $80 a rod and worst case if something needed to be balanced or done in any special way that it was going to be $150-200 a rod and that it was going to take a week to 2 weeks to do. i leave for japan again tomorrow. i have lots of pics of the engine split apart and before and after cleaning pictures. i repainted the engine mounts and bottom guard and engine covers so i did get something done in the 14 days i was home but not near as much as i wanted. but am pleased to report that there is not play in the crank at all...forward or lateral. i cut the oil filter off that had 2400 miles on it and there was absolutely no metal in it at all. everything inside the motor looked brand new so that is a great sign. rod bearings show minimum signs of wear. no scoring pitting. some nicks but i have had them in a zip-lock bag together for over a week and riding around in my wife's car and trying to figure out what size they are. i know there is supposed to be a color coding but i cant find a color stamp on them. did discover durring prep for painting that the head that i ordered didnt come with any shim buckets. so i attempted to pull them out of the FZR head and they wouldnt budge i know they just ride on there but for some reason they would go up and down with the spring but not out so i could clean them up and use them on the new engine. so i found a set out of a 92 FZR 600 and going to use them in the new engine. ok i think this is long enough i will post pics once i get them on the computer.