My FZR600R Foxeye Restoration

[dougs]

i have recently got a foxeye 600 and intend to fixup and repair so i thought i would post the progress on here.
first the bike as i got it,


first job was the seat unit it was superglued together and had broken arround one of the lugs i had to melt some plastic an form a new hole for the mounting screw

next was the top faring near the mirror was broken and a big bit was missing so i made a new piece and melt-welded it into place


next was the front indicator mounting which was ripped out and stuck back on with body filler superglue and fiber glass i had to clean it all off before i could weld it back together

and now its flush and solid so i can fill and repaint

this is the other side which i havent tackled yet but is in just as poor condition

last for now is the exhaust an ART race can (way too loud) which was making the bike run very flat as well so i fitted a baffle it was a fantastic upgrade still sounds great but now goes much better and is not always attracting attention

will post more as and when i get more fixed up

[sweekster]

Impressive work so far. Keep it up

[dougs]

i have checked the front brakes this weekend and found the pistons are seized up (testament to how good the brake are that only half the pistons are moving!! and it still stops) i found that the dust seals are soft and have expanded. so i have to get some new seals and refurb the front calipers the fluid looks as old as the bike too. p.s. thanks to whoever did the 'how to' on the flushing brakes really helpfull!

[Genesis]

Nice work

[dougs]

not much activity this week i have started to make a new chain guard from fiber glass, it just needs bondo and sanding i will add some pics very soon, my intention is to do the hugger and chain guard in white paint which is why im making new ones.
i had a ride out last night wow what i difference the brakes are awesome think i will bleed them again just to make sure i have all the air out when we got to the pub (the victoria biker pub)in coalville i had the only FZR there! out of maybe a hundred bikes!

[dougs]

ok been busy i found the oil level window was fouled up so i could not check the level

so i removed it and cleaned it now ok the oil was low too!
i then got round to the other side plastics



and i then started on the new hugger i am making
this is the chain guard all done, just needs filler and paint

and a single seat cover for the pillion




oh and most important i got a rideout on it too

[dougs]

i have been claning the bike taking parts off and cleaning up properly i am about 1/2 way through but it is beginning to show

will get loads more progress done through the winter all the riding is causing serious delays to the restoration

[yamaha_george]

D,
nice work the bike looks a whole lot better for all the work you have put in .

However your Chain guard is not legal under construction & use regs it must either contain a reinforcing plastic any old chain guard but coated and that plastic must be part of the fastening system OR your chain guard must be metal

If you read the couple of horror stories of chains breaking and maiming people on this forum you can understand why these rules are applied and the MOT will fail IF spotted.

I urge you to follow the rules & not chance it.I was lucky & got away you may not be that lucky!!!!!


Suggestion the over the chain part line with a thin steel sheet and weld shaped brackets to it that follow the fibreglass contours of the fixings inside you could even mould the steel in to the whole assembly legal inner once painted class product.
:-}

[dougs]

thanks Yamaha George i think i will scrap the chain guard idea and use the original (might coat it in carbon fiber later) dont want to rip my leg off if the chain goes glad you noticed that one ;o)
cheers doug

[dougs]

update on the rear seat hump i have about finished grp work now on to finishing and painting
the unit in primer


coming along nicely

[yamaha_george]

update on the rear seat hump i have about finished grp work now on to finishing and painting
the unit in primer


coming along nicely

Doug,
Guy that is bloody impressive looking seat hump way better than the Yamaha original which always looked like an after thought and does not fit as smoothly as yours.


PS you ever hear ok a stuff called SUGRU great DIY plastic bits maker.I used it for frame plugs on one of my bikes. good for making custom grips & quick seat cover repairs .

[dougs]

cool thanks i will look it up have got a big shopping list now what with a truck load of plastex some carbon fiber matting and a gross of stainless bolts

[yamaha_george]

cool thanks i will look it up have got a big shopping list now what with a truck load of plastex some carbon fiber matting and a gross of stainless bolts

D,
make sure you also order a tube of "copperslip" anti seize compound as Stainless steel studs/ bolts/ screws do not play nice when used in aluminium cases etc.

A little copper slip on each set of threads stops the differential metal corrosion & there fore hassles like broken studs we all have heard about recently :-{

[dougs]

i have checked the brake travel and the lever is now about touching the grips again so its time for some major overhaul work on the stoppers so i have
new(ish) R6 calipers and master cylinder purchased but i have checked the front discs and they are 3.1mm and 2.9mm thick so got to get new ones asap

[dougs]

not a good week brakes failed on the front (which i already knew about) and the rear as shot as well, when i serviced the rear it was over tightened all over and the bleed nipples were seized and blocked ended up getting a old one from the breakers and using the spares from both back brakes to make a good one the pistons were seized on both units
the useable spares i have from the two rear calipers

the refitted caliper


the front breaks removed ready for replacment with the R6 bluespots when they come

the front ready for the new calipers


got bored waiting for the new front brakes so i made a paddock stand got all the parts i needed so what the hay,

and some forks for the swing arm dont know how i am going to fit them yet

it is way easy er to work on the bike on the stand