FNG needs a little electrical and fork help

[drsfmd]

Picked up an 89 FZR 600 from Craigslist on a whim. It was sold to me as a non-runner at a great price, and after a new battery and full fuel system cleanout it fired right up and runs great.

Couple of issues I'm dealing with and could use some input.

1) Either the brake light bulbs are burned out or stuck on. The tail light comes on when the key is turned in the ignition. The brake lights do not work... BUT the tail light seems awfully bright to me. I've read old posts elsewhere that indicates that the rear break switch can get sticky. So (A) I need to figure out where that switch is located... the manual is useless in that regard. Where is it? -OR- (B) where is the wiring junction for that switch, to unplug it and test to see if that's the problem. -OR- (C) If the bulb is burned out, how the heck do I get in to that housing? I'm reading that I should be able to get at the back of the housing with the seat removed, but that most certainly isn't happening, as all of the electronics are under the seat and there's no where to get at the back of the housing from there... am I just being daft here? I'm completely at a loss.

2) The PO had the fork seals changed a few hundred miles ago, but they feel very soft to me compared to bikes that my friends have. Can the oil in the forks simply be topped off?


Edit: Also does anyone know of a site to find a service manual? I would happily buy an original or licensed reproduction, I refuse to pay for a bootleg copy, and the only copy I can find for free is in German...

Edit 2: I'm missing the side fairings... anyone know of a good junk yard that might have some? Some other used source?

[willandrip]

On the very bright tail lights.

!; If the US models are the same as UK bikes......have the bulbs been installed correctly.
UK bulbs are twin filament and offset pins.If incorrectly installed the tail light circuit operates the brake light filament.
I do NOT know if US. bulbs are similar.

2; Either the front( its under the lever) or the rear brake switch is stuck in the on position. THIS is the most likely scenario.

3. The wiring plug has been cut off and the wires jerry rigged incorrectly at the rear light.

Here is a very poor photo of rear switch location; Its behind where the footrest fits.


Just follow the wires. to find where it joins the main harness...it is a one piece black flat plug with two wires.(pretty sure wires are green and black ) If you remove the seat side panels you get much better access.

To get to the bulbs;
Remove the passenger seat....it unhooks.
The bulb holders in in the space at the very rear.
You may reach in if you have small hands.
The plastic rear panel is removeable after the seat side panels are unclipped and slid rearwards off the joiner piece.





If you can reach in and feel the caps on the end of the two sets of wires that feed the two bulbs; the plastic holder cap unscrews 1 quarter turn anticlockwise and undoes.Its like press and turn at the same time.

Notice the cap has 2 or perhaps 3 (cannot recall) alignment lugs that ONLY fit in the correct position when re assembled.


On soft forks;

The springs were notoriously weak.
They are now 25 years old and are even weaker.
Don't add more oil that recommended....you will burst the oil seals.

Empty the forks out and refill with 15 weight fork oil.
Get uprated springs.
Don't cut spacers and add preload.....it is of little help.

[willandrip]

Here is a link to manuals.....courtesy of the other FZR site.

http://www.fzrarchives.com/ipb/index.ph ... opic=36296


(Quite frankly why this site does not host it's own copy of the factory manual is somewhat embarrassing)

Read the WIKI on this site........it is particularly important you check the charging system is not giving overvoltage due to R/R failure........esp as you have just fitted a new battery and do not know the history of the machine/why it was parked up.

Ohh; Hello and welcome BTW.

[drsfmd]

Gents-

Thanks for the welcome and the help!

The brake light is fixed - it was indeed the switch-- a bit of cleaning and lubrication, and we're in business.

I suspect my bodywork is either aftermarket or was switched from a later bike, as my seat and taillight look different. I may have to pull the body work to get to it. I'll report back once I've got that figured out.

Had to order the oil for the forks online... should be in within a few days. The local Yamaha dealer went out of business a few months ago.

[drsfmd]

Here is a link to manuals.....courtesy of the other FZR site.

http://www.fzrarchives.com/ipb/index.ph ... opic=36296

You mean the site I've tried to register for three times now, without luck?

[willandrip]

The mods on BOTH these sites except one or two notable exception are very inactive nowadays.

This is the bodywork on an 89 ;





I bet someone has fitted a later ,more sporty seat unit ( R6 or similar)

[drsfmd]

My tailpiece is quite different than that one. I'll take a picture when I go out to the garage (it's pouring out right now).

Edit: If one of you guys has a copy of the service manual as a .pdf would you be kind enough to send it to me?

[DonTZ125]

The mods on BOTH these sites except one or two notable exception are very inactive nowadays.

Oh, there's a few of us still around. The issue on the Archives isn't Mods, but rather Admins. I've sent PMs and emails to various people, poking at them about the situation.

[DonTZ125]

Ok - anyone still waiting on approval for the Archives, go check again, If your account still isn't working, drop me a PM here.