Parts catalogue

[pandp]

Does anyone know where i could download a parts catalogue for a FZ400R 1986? The type with the exploded diagrams and list of parts.

[willandrip]

I doubt very much if many members have seen the FZ400 in the US.
There was a few posts on here and the FZR Archives forum.

There does not appear to be a dedicated manual or parts fiche for the 400.(It would all be in Japanese anyhow as it was only officially a Japan home market machine)

However the engine is similar but not identical to the FZR400 Genesis of 1986/87.
This is the 400U or 400UC in the U.S.... It has no EXUP system.
On a UK forum recently; a non runner FZ was resurrected using the Genesis manual/fiche.

Here is the FZR 400 fiche that can be used for some engine parts/carbs ;
http://www.cmsnl.com/yamaha-fzr400u-198 ... partslist/

The frame/chassis/running gear is supposedly identical to the FZ600 except lack of lower fairing panels,
I have no direct experience of this though.
The fiches are here;
http://www.cmsnl.com/yamaha-fz600-thund ... odel16737/

The 400 was imported to the UK as a "grey import" (all would be second hand straight from Japan)
The 600 was an official import to UK and would be sold new.

Many used parts vendors in the UK do not know the FZ is a different model to the FZR so be wary if buying used parts.
Haynes do a workshop manual that has a section on the 600; some info may be gleaned from that mayhaps !

46X is the model designation.

[pandp]

Thank you very much, that explains why i have struggled to get answers to some of my questions. Whilst searching i did find this

http://www.yamahapartsnation.com/oempar ... 600s-parts

Seems to be a lot of similarities looking at some of my parts. I think i have taken on quite a challenge with this one as it appears to be missing quite a few parts, the main one i noticed was the carbs.

Thanks for all the info.

[willandrip]

I reckon they will run using the 400 non EXUP Genesis carbs.(the ones with the metal diaphragm caps/tops)
The owner on the other forum got his to run by using the settings/parts from that model .
He too had bought it before finding it was a bit of a "pig in a poke".
I have inquired of him yesterday if he ever found any specific manuals but the reply was negative.

There are quite a few bits for the FZ model for sale on Ebay UK.

Don't get misled by FZ400/600 Fazer parts; they are later and different altogether.

A pic. of yours would be good !

[pandp]

Thanks again for your reply. Yes i must admit i have been put off a little with the lack of parts for these particular models. Having nearly completed my other build (Honda bros) i wanted something else to start, didn't realise how many variations there were .

These are the only pics of mine as i picked it up and stored it until i can start the build.

[willandrip]

Good show; at least the motor is in one piece, that will save a load of grief.
What's the plan; concourse rebuild or much better; a tidy up with some uprated parts and leave the
patina as long as it is not excessive corrosion ?

[pandp]

The plan was to have the frame shot blasted and powder coated. As with my other project i was aiming to build as near to stock as possible. I really should have done my homework before buying this though as the FZR you pictured would have been a much better project. I want to go ahead with the build but i think it all depends now on how much is missing and how easy to source the parts are. Until i go through everything i wont know. To get the bike into the car we had to remove the triple and when we did all the bearings fell out, not a major issue as wemoto stock the bearing sets providing they fit, wemoto advertise parts for the Yamaha FZ 400 N (IKF/46K/33M).

[willandrip]

Good call on the frame ; it makes it so much easier to build from a clean platform. If coating parts; I get all the bits and pieces done in one go. The extras add nothing to the original price anyhow.
I do make two lists, often with drawings of small obscure parts and stating the total number of items then give one to the coater. This way if anything is lost it can be identified and redress made.

May be worth you checking out the original shock length and comparing it to the R6 mod that is done on the FZR models.
It is a very good and cheap upgrade for a part that is nearly 30 years old now.

Where are you located to be using Wemoto ? You do not sound to be UK based !

Most of it looks to be in sub assemblies ; I do not think you will have that much trouble (as you have previous rebuild experience), a few fixings will be lost but Yamahas from that era tended to be parts bin specials that utilise items
already in production or carried them forward to the next model.

Edit; Just had a squint at the FZ shock; the common FZR/R6 mod will not work with the Fz as both ends of the Fz shock
have "eyes" rather than one end a fork. The earlier R6 shock(pre 06) is of this type though and may be of use .

[pandp]

I know what you mean with lists etc, i'm very particular when it comes to being organised.

Yes i am in the UK mate, Essex. Not from Essex but been here 12 years or so now. I do have previous build experience but i am still learning . This is how i got my last project and i thought 'what have i done'?


This is the current state, not finished but getting there


And the one before that was this

[willandrip]

Some neat work there.
Using the term "triple" rather than yokes is what made me think; not UK.

You will be sound for bits then; there's quite a bit of the stuff that is usually worn to excess, s/h on UK Ebay and cheap as chips.
I noticed the original shock seems to have an intricate method of adjustment using a remote adjuster and a toothed belt;
pleased Yamaha dropped that idea.!

You might find a look on here may help out if you get proper stuck;
http://www.400greybike.com/forum/viewforum.php?f=38

A few members have experience of the FZ.

[pandp]

Lol, sorry, most of the sites i have been on are non UK, suppose triple was stuck in the head as opposed to yoke.

Nice collection of bikes.

I am certain someone said (maybe another site) my bike would be air cooled but i have a coolant tank, rad, thermostat. Had a quick look through yesterday and so far i am missing - carbs, one upper fairing, mudguard, few pipes and nuts and bolts. The cover is off the left side of the engine, i think thats the stator, never stripped an engine so going to search on what to do, no point in fitting the engine only to find when the bike is built it is no good.

[willandrip]

No; they are watercooled; The FZ 600 is aircooled. Here you may find some more pics of the model;
http://global.yamaha-motor.com/showroom ... otorcycles
Type FZ 400R into the search box on lhs. (no direct link) you can choose colours once page loads by clicking thumbnails.

I would advise to make 110% certain that gaskets are available before you strip the engine.

You can tell a lot from inspecting the plugs if still fitted and doing a compression test on the bench.

If the plugs had burnt on oil ; it would be prudent to strip.
Turn the motor over(plugs out/rotate generator) on the bench and inspect the inlet and exhaust ports.
Observe valves.
Remove cam cover and inspect cam lobes/journals.
Remove sump and inspect crank. The sump gasket can be replaced by sealant; the cam cover gasket will be rubber/reusable.

If equipment is available; do a wet and dry compression test and a leakdown test before stripping anything.
All you require is the starter to work to do this ; no carbs needed.

If you strip the motor only to find it is in reasonable condition; you may never find the head and base gasket to rebuild it ? How did it appear to have been stored ? Any history of the stripdown by P.O ?
There does not appear to be another similar engine to this (waterpump location)

If you contact Fowlers of Bristol and enquire of parts availability and price (specifically head/base gaskets) this may influence your decisions.
You must have the frame number for reference; they will not entertain you otherwise.
Persevere if the first parts assistant is of little use; phone at a later date and hope to get a more switched on individual!

[SouthendChris]

Essex UK eh!? Give us a shout when you get it together and fancy a rideout. I am a few miles outside sunny Southend-on-Mud



Chris

[willandrip]

If you have no luck with Fowlers having parts manuals;
Get a paper copy from here;
http://japan.webike.net/ps/#!p.m=857&p.c=9900&p.sk=1

I got some manuals from them; cost was negligible and the copies good.
They arrived in ten days.
The description is in Japanese (unreadable) but the part number is as normal.

Little thread here;
viewtopic.php?f=7&t=9685

Shows pic of carbs; looks like the Genesis carbs swap would be no good; they are downdraughts.

[pandp]

You make that sound so easy willandrip . I can put a bike together, i can sort electrics but engines, well i'm not overly clued up on that. I have a feeling i'll be doing a lot of 'how to' on google.

Appreciate all your help though mate.

Hi Chris, i would love to say i'll have her together in no time but i'm doubtful. Not too far from me though, near Chelmsford.