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Project FZR400 Dragster

Discussion in 'Other Projects - Other Bikes (non 250's)' started by GreyImport, Oct 20, 2022.

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  1. Andych

    Andych Moderator Staff Member Premium Member Contributing Member Dirty Wheel Club

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    Put it this way... Iknow it works as I used it to initially get it off my trailer... by myself down a skinny ramp... it was slow coming down lol.
    Then to move it I had to try and prise the pads apart a little.....
    See yours is self supporting, unlike lots of Gen Z or whatever they are now... :)
     
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    Andych, Nov 28, 2022
    #41
  2. GreyImport

    GreyImport Administrator Staff Member The Chief Contributing Member

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    I hate rear brakes ... I never use them
    Pistons move out but wont return ... seal is perished by the look of it .... ton of dirt and dust came out of one bolt ... well maintained bit of kit as usual :commando:

    rear caliper.jpg
     
    GreyImport, Nov 28, 2022
    #42
  3. Andych

    Andych Moderator Staff Member Premium Member Contributing Member Dirty Wheel Club

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    SNAFU... but not FUBAR just yet.
     
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    Andych, Nov 28, 2022
    #43
  4. GreyImport

    GreyImport Administrator Staff Member The Chief Contributing Member

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    And some more fun and games .... very notchy steering
    A bit of clean and grease up and some proper adjustment might be enough ..... it wont be going around too many corners ;)

    steering stem 2.jpg

    steering stem 1.jpg
     
    GreyImport, Nov 28, 2022
    #44
  5. Linkin

    Linkin The Mechanic Premium Member Contributing Member Dirty Wheel Club

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    At least they are tapered rollers, someone has done them before but has not greased the bearing properly. Or not wiped down the races with a dry cloth after sticking them in the freezer to shrink them for fitting. If the seals were fitted backwards they let grease out and water/dirt in. Did a set of bearings on a KLR650 that were like that.

    Better check that the frame has recesses in it to knock out the races. If not, it turns a mildly easy job into a complicated one. Best method I have found if there is no recess to knock the races out, is to grind them out with an air powered dremel using a ball shaped bit. You have to grind through the race completely to release the tension and minimise 'oopsies' into the frame.

    That said, every time I've had to do that, after the old race is out, I grind out 2 sections in the frame for each race so they can be easily knocked out in the future (if they are not present as standard). Save the next guy some trouble, because it might be you again.

    Oh and little bikes with ABS like the new CBR250R suck to do steering bearings on, because they have hard brake line blocks bolted to the frame directly in the way of the lower race :headbang:Thanks Honda for that one!
     
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    Linkin, Nov 28, 2022
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  6. Murdo

    Murdo The Good Doctor Staff Member Contributing Member Ride and Events Crew

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    If they are nochy then you are going to have to replace them, cleaning wont get the bumps out.
     
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    Murdo, Nov 29, 2022
    #46
  7. GreyImport

    GreyImport Administrator Staff Member The Chief Contributing Member

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    Sometimes the little stuff can be satisfying
    Refurbished clutch perch for those lightning gear changes and new grips
    Cant find any screw in bar ends though .... I have some from the 250s but they are smaller

    PXL_20221129_031556649 (Medium).jpg

    PXL_20221129_031731043 (Medium).jpg
     
    GreyImport, Nov 29, 2022
    #47
  8. Murdo

    Murdo The Good Doctor Staff Member Contributing Member Ride and Events Crew

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    Measure the thread diameter and go to Bearfast and get two dome head cap screws.
     
    Murdo, Nov 29, 2022
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  9. Linkin

    Linkin The Mechanic Premium Member Contributing Member Dirty Wheel Club

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    Linkin, Nov 29, 2022
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  10. GreyImport

    GreyImport Administrator Staff Member The Chief Contributing Member

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    Those bar ends are cheap enough to take a punt :thumb_ups:

    Head stock kit will be on the parts buying list .... the top seal is AWOL anyway
    Ill be putting it together temporarily until the the new stuff arrives as it has to be there to support the front end with the front stand ... its currently balancing precariously on the jack

    Thats "grease' not rust :cool:

    PXL_20221129_075001793 (Medium).jpg
     
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    GreyImport, Nov 29, 2022
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  11. Linkin

    Linkin The Mechanic Premium Member Contributing Member Dirty Wheel Club

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    Beware the all balls listings for grey import bikes, they are wrong for the ZXR250. The kit they supplied was mainly for dirt bikes. Big bottom bearing and far smaller top one. ZXR250 ones are the same size top and bottom. Probably faster to go to the local bearing shop, but that leaves you without new seals. I always end up destroying the bottom seals.

    Oh and I don't bother cutting the cage on lower bearings to remove them, nor heating them, nor grinding them anymore. I go straight for the chisel punch and hammer, lock the triple in the vise and bash away, they come off easily. If it gives real trouble or is totally stuck, then out comes the death wheel (grinder).
     
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    Linkin, Nov 29, 2022
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  12. GreyImport

    GreyImport Administrator Staff Member The Chief Contributing Member

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    Last edited: Nov 30, 2022
    GreyImport, Nov 30, 2022
    #52
  13. GreyImport

    GreyImport Administrator Staff Member The Chief Contributing Member

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    New throttle tube maybe required :cool:

    PXL_20221130_025103906 (Medium).jpg
     
    GreyImport, Nov 30, 2022
    #53
  14. ruckusman

    ruckusman White Mans Magic Master Premium Member Dirty Wheel Club

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    Some, but not all lower races will come off with subtle persuasion - I keep a "beater' chisel that can penetrate the gap and get things moving, I sharpen it occasionally when the edge gets buggered.
     
    ruckusman, Nov 30, 2022
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  15. GreyImport

    GreyImport Administrator Staff Member The Chief Contributing Member

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    Were the carbys a bastard to get off ? ... but of course
    Intakes are dodgy on the outside but look fine on the inside
    Bowls still have the original JIS screws and have been removed but not butchered thankfully

    PXL_20221201_000008246 (Medium).jpg

    PXL_20221201_000021986 (Medium).jpg
     
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  16. jmw76

    jmw76 Well-Known Member

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    Those intake rubbers look a bit sad.
     
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  17. GreyImport

    GreyImport Administrator Staff Member The Chief Contributing Member

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    GreyImport, Dec 1, 2022
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  18. maelstrom

    maelstrom LiteTek Staff Member Premium Member 250cc Vendor Contributing Member

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    Fascinating, only the 3EN2 used the one piece rubber manifolds like the 3TJ1. Your swingarm is also a giveaway that it is a 3EN2.

    3EN1
    3EN1.jpg

    3EN2
    3EN2.jpg

    The part numbers on those Chinese things are for the FZR600 but they should work fine.
     
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    Last edited: Dec 1, 2022
    maelstrom, Dec 1, 2022
    #58
  19. maelstrom

    maelstrom LiteTek Staff Member Premium Member 250cc Vendor Contributing Member

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    Brochure.
     

    Attached Files:

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    maelstrom, Dec 1, 2022
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  20. GreyImport

    GreyImport Administrator Staff Member The Chief Contributing Member

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    So next problem ....
    #1 plug is cross threaded
    Explains why the plug cap wouldnt go on properly and now why the plug socket wont go on the plug as its sitting on an angle
    And of course access is a bitch .... Ill have to find something to clamp on the ribs maybe
    Some people shouldnt play with tools :headbang:


    PXL_20221202_111547858 (Medium).jpg
     
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    GreyImport, Dec 2, 2022
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