YZF600 carb swap part II

[match417]

Since I just picked up an 04 yzf600 to part out (the same one i pulled my carbs off of a couple months ago), I've been looking at the bikes side by side thinking about what to do since I don't have the cash to buy new fzr manifold boots or even used ebay ones. I've always had it in my mind to put on the entire harness w/ cdi, relays, and gauges. Not only to bypass my rewire for the FZR signals to work with my yzf600 switches, but also to take advantage of the TPS that is on the YZF carbs, but i have a hunch that the TPS won't do me much good with the FZR engine because it will retard the timing when i roll hard on the throttle. I'll probably put the YZF rubber heat shield above the head on too along with the coils that are right there. When i'm done with this I will literally have everything on it YZF except for the engine, front forks and frame....my fairings will be 05 YZFR6 eventually, once i find wrecked ones for free, and if no one buys my YZF600 swingarm/tire..guess who's putting on his bike??? (this doesn't mean that I'm not selling the swingarm, buy it if you want it, it'll take me a year to get around to changing it out) And to have a newer part of the drivetrain, i might put the whole transmission assy on too, since the_finch is getting the block internals/head and cad600 is getting the case, that leaves me with the trans, and who's gonna buy a friggin trans?!?!

Three cooling system ideas..
1) Put the whole cooling system on there! I tried to put the intake manifolds on the fzr tonight, they are too wide, and the cooling pipes that go between cyls 1/2 and 3/4 get in the way. So I have to take them off, but I have a full YZF cooling system now, and the connections aren't that much different than the FZR's. The only issue I see is the cooling pipe behind the rubber manifolds. The mount screws are in different places between the two bikes. I already have a way around that though. The YZF thermostat is mounted behind the carbs anyway on the right side of the engine behind the peanut. And the temp sending unit comes off of this into the harness, as opposed to being under the fron of the gas tank, so if I pulled this off and put it on my bike i'll be freeing up tons of space under the front of the gas tank.

2) I could cut off the metal tubes that run between cyls 1/2 and 3/4 and run two rubber hoses from them into a Y connector, take the thermostat housing and hose (from YZF) from it to the radiator and take the radiator (from YZF) off too, then leave the hose on the left side of the bike that runs from the radiator to the waterpump (leave both stock FZR). But the only real difference between this idea and the one above is that I won't be using the pipe behind the yzf carbs.

3) this is more far fetched..but I take the FZR cooling system piping, cut it, and sweat copper fittings to it so i can run it into the thermostat, but it's just easier to do # 2(haha haha...i said "do # 2"(yes i know..it's lame..but i should have gone to bed 2 hours ago, instead i was out playing with the bike with a flashlight and had an inkling to post my thoughts on here for you guys)), this is just an idea, but while i'm at it, why not just sweat copper all the way around? Only use short rubber hoses to connect things.

Whichever one i decide to do, both will free up that space under the front of the gas tank and both will give me a radiator cap that's actually on my radiator. And both will almost require me to do the harness swap because of the difference in the location of the sending unit, but i could run a few wires across the harness if need be.

AAAHHHH complications..i want my bike done! I should have my dad send me my other FZR carbs in the mail, but that bike is in 100 boxes. Ugh, leave it to me to want to modify everything. Including modified xbox's and hacked linksys wireless routers (woohoo)..I should seriously slow down modifying everything...AFTER i finish the bike...

[cad600]

As far as the cooling goes, take a look at page ten on this http://www.fzrarchives.com/ipb/index.ph ... 941&st=135

About half way down, you'll see what I was doing to put the YZF temp unit in the typical YZF place. It seemed to work well.

[match417]

thats almost exactly what i have in mind, but what i was planning doesn't T down in the middle of the engine, i was planning on running it into a copper Y fitting bought from the household plumbing section for better flow. Or I could just recreate the YZF metal hose setup with rubber hose, an elbow, and a T fitting. Glad to know someone else has already done what I was planning. So did you just relocate the stock FZR housing or use the YZF parts?

[cad600]

I used the YZF parts. You'll be surprised at how little room there is when you start putting it together. In terms of pipe fittings.

[match417]

So thanks to 95fzr600 saying something about if he was in Hawaii his bike wouldn't be sitting for 4 months..i went out and put a little time into it. I pulled the cooling system off and took out the manifolds as well, the manifold bolts haven't been off in 20 years, so I had vice grips around the top of my hex key praying that it wouldn't snap or twist. Got the new manifolds on, and after spending literally about an hour of trying to force the carbs in at every angle..i realized the intake rubbers weren't lined up properly, so the bolt holes on the manifolds have to be dremeled out a hair so that it's centered on the ports in the head, otherwise the carbs won't fit..trust me... I attached a few pictures so you guys can see the difference in size and height. Also if you look down the manifolds you can see that they aren't centered on the holes. I'll elongate the bolt holes in the manifolds tomorrow probably. I really have to seal up the engine with something better than plastic bags, these carbs have to go in, I can't have it get rained on. Most of the time it's parked under a carport, but i had to move it out tonight. Hope it doesn't rain.

Once the carbs are in, I also plan to install the pressure equalization system (I'm gonna call it PE system for short), the air tube in the center of the carbs that I don't know what it does, except that it has something to do with PE in the carbs, is going to eventually run through the plastic shield above the head and under the lower triple tree into the rest of the PE system tubing. I don't know what it does, but I have felt my friends YZF run like my bike when it's disconnected, then when it's connected it's waaay more responsive. So it's being utilized! I'm also going to dremel holes in the frame for the stock YZF airbox and reinforce that area with a couple welds. But the coil pack is in the way, so it's going to be relocated. I'll have to figure out what to do with that.

[match417]

I can't have it get rained on.

yes, i just quoted myself...it just started raining..maybe it won't be as windy as it has been..the tank should cover the engine well enough..i hope.

[95FZR600]

Go get a cheap MC cover to put over it from wally world or something.

[match417]

no dremeling required..i put the manifolds labled "R" on the left, and the manifolds labeled "L" on the right. I was hoping it would work since the offset between the carbs would be different than if the R's were on the right and L's were on the left. And it works! ha! The only thing now is the intake ports have to be dremeled a hair to match because the yzf manifolds are oval shaped on the engine side and the fzr manifolds are round. It's only a couple millimeters. But they fit! thats the main thing. Now I have to move the coils out of the way so the airbox will fit. After a small mockup, it looks like it might fit under the gas tank, but I can't tell with the coils in the way. I'll work on it more tomorrow night.

and 95, winds can get too strong here for a cover. wind has ripped my friends car cover to shreds..all of the seams are ripped up, but he still leaves it on his car for some reason. We had 50 mph gusts the other night.

[megaloxana]

what no video?

[match417]

what no video?

naa..no pics either..i only put 10 minutes into it today because i checked out my friends car then hung out with her most of the rest of the day..cute girl vs motorcycle...cute girl wins by a long shot.

[yamaha_george]

what no video?

naa..no pics either..i only put 10 minutes into it today because i checked out my friends car then hung out with her most of the rest of the day..cute girl vs motorcycle...cute girl wins by a long shot.

And another one bites the dust, a real nice girl would be handing you spanners to work on the bike...............

[match417]

yes, but finding a girl that knows the difference between a 12mm 6 point deep socket and a spanner wrench will be a little hard. Or if she did know the difference, even better if she had the ability to look in a toolbox and try to find a 12mm by eye instead of picking up every one she sees and reading them off until she finds the needle in the haystack. It's quicker to walk to the toolbox and grab what I need. Otherwise if she knew what tools to grab by eyeballing the size, she would probably know enough about engines to help me and not hand me tools.

You're funny "another one bites the dust"..

[match417]

i still don't have the money for the fork seals and fork oil, so i'm kindof taking my time with finishing the carb swap. Plus i still need to buy individual air filters. I managed to figure out a way to route the throttle cables since they are about a foot longer than the FZR ones. I ran them through the hole in the frame where the fake air tubes went, and i ran them around the left fork and up to the throttle. And i still have to set up the new water tubes into the thermostat. I have some copper pipe fittings, i have to borrow my friends plumbing stuff and sweat them together. Then i can run them to the thermostat housing and put on the YZF radiator.

On a different note, I now have both upper and lower right side R6 fairings, none are cracked or damaged, the upper just has some light scratches. One of the mount holes lines up with the old FZR mount hole. I have to make the other ones. But since they are all from different bikes, and there are only 4 colors to the R6, of course i have 4 different color pieces..what are the odds... Why can't i be like shred and get all black and two blue?

[mossy1200]

yes, but finding a girl that knows the difference between a 12mm 6 point deep socket and a spanner wrench will be a little hard. Or if she did know the difference, even better if she had the ability to look in a toolbox and try to find a 12mm by eye instead of picking up every one she sees and reading them off until she finds the needle in the haystack. It's quicker to walk to the toolbox and grab what I need. Otherwise if she knew what tools to grab by eyeballing the size, she would probably know enough about engines to help me and not hand me tools.

You're funny "another one bites the dust"..

My wife would bleed my brakes,swap out wets to slicks and change my oil and filter all before i got through my 2nd beer.Its good to be me.LOL

[match417]

My wife would bleed my brakes,swap out wets to slicks and change my oil and filter all before i got through my 2nd beer.Its good to be me.LOL

hahahaha! what a life..