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New Member 1989 FZR250R

Discussion in 'New Members Say Gday' started by manynathans, Nov 8, 2020.

  1. manynathans

    manynathans Active Member Premium Member

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    got most of the subframe built back up today and the front fairing bracket and clocks fitted.
    IMG_20220109_164240_040.jpg IMG_20220109_164209_401.jpg IMG_20220109_164225_270.jpg
     
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  2. manynathans

    manynathans Active Member Premium Member

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    Swingarm, shock link and sidestand bracket painted today, looks like the apprentice was given the job of welding the swingarm together in the factory, not pretty. Need to give the paint some time to harden up and fit new seals then onwards with reassembly. IMG_20220111_162713_222.jpg IMG_20220111_162720_694.jpg
     
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  3. jmw76

    jmw76 Well-Known Member

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    Is that really factory welding? It is very different from what I see on my Hondas.
     
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  4. GreyImport

    GreyImport Administrator Staff Member The Chief Contributing Member

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    Yea welding was not one of Yamahas high points back then .... at least this one of mine looks to be done by a second year apprentice ..... I think yours was done by the tea lady :D

    Did u clean out all those rollers bearings and pack them with new grease? .... FZRs are known for their rear end "squeak"

    IMGP0080.JPG
     
  5. manynathans

    manynathans Active Member Premium Member

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    Looks like I got extra value from the tea lady then, even more weld spatter than yours! Bearings are all cleaned out, want to replace some of the seals and will make sure everything is well greased before it goes back together. Having fun cleaning the rear shock at the moment, The spring looks great but theres lots of ingrained dirt on the shock body itself. Guess its years worth of tyre rubber and road tar. Many hours with a toothbrush required.
     
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  6. Yetiburger

    Yetiburger Well-Known Member Premium Member

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    Yeah my swing arm welds look pretty abysmal as well .
     
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  7. manynathans

    manynathans Active Member Premium Member

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    Back end back together today and sitting on its wheels again, they will be the very last thing to be overhauled.
    Next on the list is rebuild the rear brake master cylinder and fill and bleed the system. Paint a few brackets, then time to get the engine in. Its only been out for the last 20 years!
    IMG_20220113_190048_916.jpg IMG_20220113_183612_172.jpg IMG_20220113_183601_681.jpg
     
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  8. manynathans

    manynathans Active Member Premium Member

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    Got my dad to give me a hand and we got the engine back in today, need to clean up the bolts and things for the front engine mounts before fitting those back and tightening everything up. Also got the rest of the rear brake system built up.

    Also heard back from the aliexpress seller about the new fairings, they are all painted and are on their way over to me. They sent me some photos of the completed painting before shipping, I have included them here. IMG_20220122_140201_129.jpg IMG_20220122_140230_715.jpg IMG_20220122_130656_578.jpg IMG_20220122_130705_824.jpg 1.jpg 2.jpg 3.jpg
     
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  9. GreyImport

    GreyImport Administrator Staff Member The Chief Contributing Member

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    Looks great :thumb_ups:

    If you find this in your parts bin , its a fairing bracket ..... hangs from the sump bolts

    fairing bracket.jpg

    filter 1.jpg
     
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  10. manynathans

    manynathans Active Member Premium Member

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    Well spotted, I have one of those and had no idea where it went, was hoping it would eventually reveal its true purpose to me as the build progressed. Is there supposed to be a little bend in it towards the tip of the triangle part or should it be flat all the way? My previous fairings were looking extremely second hand so had no idea if the bracket has a bend in it too or if its supposed to be like that.
     
  11. GreyImport

    GreyImport Administrator Staff Member The Chief Contributing Member

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    Looks like its supposed to have a bend
    Its pretty common for aftermarket fairings to not "fit" exactly for any bike so Ill guess you will eventually see if it sits right or needs some tweaking anyway

    IMGP0086.JPG IMGP0085.JPG
     
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  12. manynathans

    manynathans Active Member Premium Member

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    Finished fitting the engine mounts and bolting everything up nice and tight today. Filled and bled the rear brake system. And opened up the box of coolant system bits and started piecing things together. Would anyone have a picture of the bike under the tank so I can see if there is a bracket that holds the thermostat housing in place, and what ay the wiring loom and connectors sit in that area? Thanks

    IMG_20220127_153606_555.jpg
     
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  13. GreyImport

    GreyImport Administrator Staff Member The Chief Contributing Member

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  14. manynathans

    manynathans Active Member Premium Member

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    Sorry to be a bother but does anyone have a picture of the top of the radiator where it mounts to the frame? I assume there should be a bracket attached to the frame that supports the top of the radiator. No idea what it looks like though
     
  15. GreyImport

    GreyImport Administrator Staff Member The Chief Contributing Member

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    FZR rad bracket.jpg IMGP0106.JPG IMGP0105.JPG
     
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  16. manynathans

    manynathans Active Member Premium Member

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    Hmmm, had a look through the remaining parts and I seem to be missing that one. Will have to see if I can find a used one on ebay.
    I do have this bracket though, but no idea what its for.
    IMG_20220207_133130_189.jpg
     
  17. GreyImport

    GreyImport Administrator Staff Member The Chief Contributing Member

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    Thats for the headers

    IMGP0110.JPG


    IMGP0109.JPG
     
  18. manynathans

    manynathans Active Member Premium Member

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    Got some time to do a bit more on the bike today, stripped all the parts off the radiator, gave everything a good clean, straightened some bent fins and painted it all black again. Coolant system is now filled and back together, the LiteTek hoses look well.
    Found someone breaking an fzr250 locally and was able to source the top radiator bracket and rubber flap thing that attaches to it.
    Not too much left to do now before I can start it up, just the exhaust system to take care of and carbs to be rebuilt. Probably wont get a chance to get near the bike again for another week or so. IMG_20220214_205122_617.jpg IMG_20220214_205103_550.jpg IMG_20220214_205110_841.jpg IMG_20220214_205050_827.jpg
     
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  19. GreyImport

    GreyImport Administrator Staff Member The Chief Contributing Member

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    Bike is looking great! :thumb_ups:

    The intake manifolds are stamped with the cylinder number as they arnt all the "same"

    Your number 3 isnt correct .... as in the clamp screw head isnt pointing in the right direction like the others .... in other words , when the carbys are on u can get a screwdriver from the gap each side under the main frame rail
    Sounds like a minor thing but when the carbys need to come off and back on countless times (its an FZR250!) it makes things much easier


    intake manifolds fzr.jpg

    IMGP0153.JPG
     
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  20. manynathans

    manynathans Active Member Premium Member

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    Little more done today, take one moderately crusty exhaust, few hours with a wire brush in the drill and some paint after. And a nice new danmoto slipon to complete the look. The original end can had rotted out, when I turned it on its end it spilled its guts over the floor.


    IMG_20220218_210306_587.jpg IMG_20220218_205851_616.jpg IMG_20220218_163302_658.jpg IMG_20220218_160100_650.jpg IMG_20220218_160056_636.jpg
     
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