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Help Advice on engine rebuild - FZR 3LN

Discussion in 'Yamaha 250cc In-Line 4's' started by FZRFANMICK, May 20, 2015.

  1. FZRFANMICK

    FZRFANMICK Active Member

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    hey all, just acquired an fzr250rr, a 3ln I'm told which the previous owner advised me started to tap and rattle, being a bright person he ignored the noise which turned into a loud banging, clapping noise and a loss of power. He didn't ride it again but was able to start it. It has sat for a month or so and now won't start at all. I have now taken possession of the bike and plan on stripping it down for a rebuild. Any help with regards to tools I will need and any other help would be greatly appreciated. I am making an engine stand to make things easier so if anyone has a pic of a good engine stand for the project I'd love to see them. I will be taking a lot of photo's and video to help with re-assembly, but if there is any literature that will be helpful please let me know as this is my first attempt at such a project. Hopefully the damage won't be major and costly but I'm looking forward to a fresh engined FZR. I have a thread going on a restoration as well, so I'm looking forward to the beginnings of a healthy collection. Any suggestions and advice will be graciously accepted. Thanks in advance. Mick
     
    FZRFANMICK, May 20, 2015
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  2. Damus

    Damus She is a BEAST and riding it is comparable to sex Dirty Wheel Club

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    I am no expert being that the fzr service manual is in Japanese its gonna be a hard journey I bet.
    Description of symptoms could be:
    - crank bearing
    - valve clearance
    - timing chain/tensioner
    probably worth replacing the spark plugs also.

    torque wrench and socket kit would go along way =p.
    Certainly not a mission I would undertake though haha.
     
    Damus, May 20, 2015
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  3. Linkin

    Linkin The Mechanic Premium Member Contributing Member Dirty Wheel Club

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    Do not start the bike.

    Take off tank, airbox, carbs, radiator. Remove spark plugs and leads (label both), pull off rocker cover. Remove stator cover. Drain coolant and oil.

    Rotate crank and feel for resistance. Inspect which valves are open on the cam when resistance is felt. That may be your culprit - valve clearance or specifically lack thereof.

    If you get no resistance when rotating crank then it may be the cam chain. Undo the centre bolt of the tensioner, and pull it out along with the springs and washers. Then undo the tensioner body and pull it out. Note the position of the ratchet. If it's fully extended, the cam chain may be stretched. Mine was stretched by 5mm compared to the new one. Another second hand tensioner did not help with the original chain so replacing the chain was the only option.

    If it were me, I would pull the head and make sure nothing is in there that shouldn't be (spark plug electrode fell off, or pieces of valve). You would be well advised to order a new head gasket and cylinder base gasket.

    Please check the frame number (right hand side of headstock) and engine number (above clutch cover or somewhere else on the engine) and post them. Along with some pictures of the bike in general.
     
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    Linkin, May 20, 2015
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  4. maelstrom

    maelstrom LiteTek Staff Member Premium Member 250cc Vendor Contributing Member

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    maelstrom, May 20, 2015
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  5. GreyImport

    GreyImport Administrator Staff Member The Chief Contributing Member

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    Use the FZR400 manuals as a guide

    https://drive.google.com/file/d/0ByHbiu0yM2SGZDZlVEY3TU5FdlE/view?usp=sharing

    https://drive.google.com/file/d/0ByHbiu0yM2SGUWhXVG0wQ2hvMDg/view?usp=sharing

    Be prepared to be meticulous and precise .... if its not rebuilt absolutely right u are wasting your time and money.

    As you already know parts can be hard to find and/or expensive .... it could something as simple as the cam chain so dont go buying up bits until you know they are needed.

    Get a breaker bar .... leverage is the key

    http://www.supercheapauto.com.au/on...2-Drive-450mm.aspx?pid=215990#Recommendations
     
    GreyImport, May 20, 2015
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  6. FZRFANMICK

    FZRFANMICK Active Member

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    Thanks for all the good advice. I'll definitely be using it and hopefully it is a problem that doesn't require the rebuild. I'll put up some pics and the other info on Friday and update you all with what is happening as I do it. Thanks again, your a great bunch of blokes and I appreciate everything you've done, cheers. Mick
     
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    FZRFANMICK, May 20, 2015
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  7. GreyImport

    GreyImport Administrator Staff Member The Chief Contributing Member

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    GreyImport, May 20, 2015
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  8. Mclaren

    Mclaren Well-Known Member Contributing Member

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    Big project when I had mine I looked at engine parts can be found but expect to pay but look forward to seeing results as much as I love my race cbr every man has one but my fzr got a lot of looks ran mint and pulled like a $2 hooker lol
     
    Mclaren, May 20, 2015
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