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Project Joker's Angry Fizzer 400

Discussion in 'Other Projects - Other Bikes (non 250's)' started by Joker, Nov 4, 2016.

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  1. MashtX

    MashtX Well-Known Member

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    I just remembered I had the same issue Stu, when I ordered my 400 Gasket kit I noticed the seals were those brown and metal ones where as the OEM ones are green viton so I had to order a separate set of stem seals and to this day have a set of the brown ones doing nothing

    Sent from my HTC_0PJA10 using Tapatalk
     
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    MashtX, Jan 2, 2017
    #101
  2. Joker

    Joker See "about me" for contact details. Contributing Member

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    Hmmm what a pain in the rear. I'll try the 250 ones on there because they seem to fit fine. The seller says the 250 and 400 ones are the same so here's hoping.
     
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    Joker, Jan 2, 2017
    #102
  3. Andych

    Andych Moderator Staff Member Premium Member Contributing Member Dirty Wheel Club

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    As mentioned earlier in the thread (not by me) check the valve stem sizes... if the stem size is different you will prematurely wear (dramatically) the stem seals and potentially the valves...
     
    Andych, Jan 2, 2017
    #103
  4. Joker

    Joker See "about me" for contact details. Contributing Member

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    Already checked, seller said they're exactly the same.
     
    Joker, Jan 2, 2017
    #104
  5. ruckusman

    ruckusman White Mans Magic Master Premium Member Dirty Wheel Club

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    ruckusman, Jan 2, 2017
    #105
  6. ruckusman

    ruckusman White Mans Magic Master Premium Member Dirty Wheel Club

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    ruckusman, Jan 2, 2017
    #106
  7. Andych

    Andych Moderator Staff Member Premium Member Contributing Member Dirty Wheel Club

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    I can't find the stem size for the FZR250 3LN but the 400 is 4.475 Inlet and 4.460 Exhaust... they are the "nominal diameters.. and Megazip also shows them as different part numbers. Main difference is HZ prefix for 400 and 3LN for 250

    The risk you take I guess when playing with non genuine spares for so many "similar" models.
     
    Andych, Jan 2, 2017
    #107
  8. ruckusman

    ruckusman White Mans Magic Master Premium Member Dirty Wheel Club

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    For the 2KR Stem size is nominal 4mm (3.975 intake 3.960 exhaust), it was reduced to nominal 3.5mm for 3LN series (3.475 intake 3.460 exhaust)

    So you could hypothetically stuff a 4.5mm stem through a 3.5mm seal, not worth doing however
     
    ruckusman, Jan 2, 2017
    #108
  9. Joker

    Joker See "about me" for contact details. Contributing Member

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    Yep... goop gets into everything.

    20170113_203358.jpg

    Glad all that is cleaned out. Engine is coming together now:

    20170116_121347.jpg

    Starting to replace all the gaskets from the kit while I'm at it, clean the goop off. Some donkey used clear silicone around the oil filter cover what a pain that is. Glad wemoto has so many parts available including the o-ring for a few bucks. So much easier to get parts than the 250.

    Also... Is something missing from the clutch pressure plate here i wonder...?

    20170116_121947.jpg
     
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    Joker, Jan 16, 2017
    #109
  10. my67xr

    my67xr Bike Enthusiast Staff Member Premium Member Contributing Member

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    I'm pretty sure the clutch adjuster is on the other side of the engine near the front sprocket area on a FZR400
     
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    my67xr, Jan 16, 2017
    #110
  11. Joker

    Joker See "about me" for contact details. Contributing Member

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    Figured out yesterday I need 37nM for the head bolts... my wrench only goes up to 22 so a new one is on the way.
     
    Joker, Jan 16, 2017
    #111
  12. my67xr

    my67xr Bike Enthusiast Staff Member Premium Member Contributing Member

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    Is it a 1/4 drive ?
     
    my67xr, Jan 16, 2017
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  13. Joker

    Joker See "about me" for contact details. Contributing Member

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    Yeh that's what I have. New one was only $50 figured I may as well invest.
     
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    Joker, Jan 16, 2017
    #113
  14. Joker

    Joker See "about me" for contact details. Contributing Member

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    Guess what im doing this weekend...? Everything's here now, getting very close... (wow the amount of times I've said that, I must own FZR's)...

    20170120_181108.jpg
     
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    Joker, Jan 20, 2017
    #114
  15. my67xr

    my67xr Bike Enthusiast Staff Member Premium Member Contributing Member

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    Nice
    Do you have Allen head socket's for the head bolt's to suit the 1/2" drive torque wrench ?
     
    my67xr, Jan 20, 2017
    #115
  16. Joker

    Joker See "about me" for contact details. Contributing Member

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    Yep got all those for the other torque wrench so all set. Will hopefully have the timing set up tonight ready to put the engine back in tomorrow!
     
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    Joker, Jan 20, 2017
    #116
  17. Joker

    Joker See "about me" for contact details. Contributing Member

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    Might seem a silly question, but the timing marks on the cams (the little dots) to they align on the magneto or the clutch side...? The FZR250 is opposite, t mark one side timing dots the other but according to this it looks like same side:

    upload_2017-1-21_14-39-7.png

    Damn I can't remember. @maelstrom with your 400 would you know please? surely they're opposite sides like the 250...?

    The second photo down appears to shown the marks lining up above the magneto which is the same side as the T-mark.
     
    Joker, Jan 21, 2017
    #117
  18. my67xr

    my67xr Bike Enthusiast Staff Member Premium Member Contributing Member

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    Don't the cam's only fit one way around ?
     
    my67xr, Jan 21, 2017
    #118
  19. Joker

    Joker See "about me" for contact details. Contributing Member

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    No they seem transferable both ways. I've sussed out what I can and I believe the marks are the same side as the magneto... seems to line up correctly.
     
    Joker, Jan 21, 2017
    #119
  20. ruckusman

    ruckusman White Mans Magic Master Premium Member Dirty Wheel Club

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    Second photo shows the timing marks on the LHS - that's the inlet tracts visible in the upper portion of shot above the gasket edge and the exhaust studs visible in the lower part of shot below the gasket edge.

    All three photos in that sequence are from the same directions/orientation
     
    ruckusman, Jan 21, 2017
    #120
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