Project 1989 FZR 250R EXUP Bike-in-a-box rebuild

Hi everyone, here are the images my mate sent me:
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So first thing will be rolling chassis, followed by wiring loom and electrics, engine, cooling, small ancilary's then fairings, then i can start to work on it, nothing too major, valve clearances (which ill do before the engine goes back in the frame), carb clean, carb vacuum adjustment, check engine compression, replace a few bearings, new paper gaskets, oil change, stripdown the brakes and powdercoat before reassembly, then give it a bit of a blast and maybe get it dyno checked for a final carb adjustment.

it looks really clean, its only done 11k miles...gonna be so nice to work on a bike thats a) not covered in 1" of road crap, and b) not rusted up with every bolt snapping!

more to follow, it gets here on saturday.

 

don't forget to use locktite on the important bolts

 

yes, im gonna print off the microfiche/parts diagrams to use as reference as i kinda know how the bike should be put back together, but as im doing it blind i would like a bit of guidance, once ive done it once it will be stored in my memory and ill be ok with it.

and thanks to whoever gave me premium/contributing member status, really appreciate the generosity.

 

As long as you don't become the "basket case" during the fun!

 

see it does get sunny in england!


clean area ready for more bikes


boxes as they were dropped off to me


rebuild commences








ignition needed a new box


not bad for a few days considering ive never seen the bike, ive only got the microfiche to rebuild from, most of the bolts were used when painting the frame and are junk, and most are in the wrong box or unlabelled. only missing a few seals here and there and the cush drive bearing for the rear wheel, hoping to get most ancillary bits done soon, then engine in, wiring on, before stripping it back again and doing a proper rebuild.

 

Ive got a leather chesterfield rocking chair in the conservatory...i like to think im a Bond villain whilst she sits on my lap and chunters at the birds in the garden

it might be a bit difficult to see, and i may take an individual picture of them, but does anyone know where the two brackets go that are in the second picture i originally posted, that are immediately to the left of the white radiator fan?

also, as the manual is in japanese does anyone know the following torque settings:
3 bolts on suspension tri arm
dogbone connection to swingarm
top of shock connection to frame
swingarm pivot bolt
front/rear wheel spindles

thankyou very much for all the help so far

 

Preliminary gasket looks all good...I'll make the outlines for the others tomorrow, weather depending, then I'll put the .dxf files on here so if you have access to a cutting machine/plotter you can make your own, or take them to a company and get them to do it. Either way, a good deal cheaper than Yamaha...

 

bit of a delay in posting, but here we go:

rocker cover off, lets take a measurement of the shims and replace any that need it


most are ok but a few have tightened up and some are too big a gap, now all back to mid-range


engine all ready to go back in the frame


engine in, not much more to put on before stripping it back


added the electrics and some ancillary bits, now its ready to repair the necessary bits


i stripped the forks, cleaned everything through to get rid of the old oil and gunk in there, new oil and dust seals (bushes are fine for the moment), added necessary oil, added a bit more oil and set the air gap a little smaller to 95mm (originally 106mm) as he would like it a little firmer at the front.


removed the brakes, cleaned them, removed pistons and seals


then sent them for powdercoating, have got fresh seals here ready to go in


replaced the missing bearings and seals from the sprocket carrier, new chain fitted and tensioned along with new f/r sprockets


finished off the gaskets


cut them


and fitted the engine covers


stripped the carbs right back, sent them to a friend to sonnicate, ill do the jets and small bits here myself


cut and stripped the old clutch cable


and replaced it with a new inner cable, no notching now and a much smoother and lighter action

new electrical connections for the rear indicators


and a new connection box for the ignition completes the electrical side of things


pretty much how the bike currently looks


need to get the brakes back on front and rear, get the carbs back and assemble them and fit them, airbox and fuel tank on, test the electrics and then see if we cant fire the old girl back up

 

that coming along really well, you a top mate for doing all this work for him

 

coming along very nicely! Good job!

 

Impressive! Should go and ride really well . When finished, you can enjoy a few warm beers...

 

cheers guys, i keep thinking about setting up a japanese 80's/90's restoration business and doing it part time on the weekends/nights, cant quit my day job, it pays too well

 

Mate if you fixed other people's basket cases like this one you can charge whatever you want!!!

Will be very happy to see this one in it's completed glory. Keep it up

 

Wow, thats just outright impressive! good on ya mate!