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Project FZR400 Dragster

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

  1. Linkin

    Linkin The Mechanic Premium Member Contributing Member Dirty Wheel Club

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    Try a thin walled spark plug socket. I had a cross threaded plug on my first 3LN thanks to a dodgy car mechanic. Luckily the thread was ok as the plug was only in about half way.
     
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  2. GreyImport

    GreyImport Administrator Staff Member The Chief Contributing Member

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    Yea the old school mower spanner fits in but cant be turned of course ....I cant even get any turn on it the way the plug is sitting .... Ill have to go plug spanner shopping or do some remodelling
    Sadly this plug is close to being fully in .... why would anyone keep forcing it in ... morons

    Hopefully its just chewed the plug thread

    Need something like this

    plug spanner.jpg
     
  3. GreyImport

    GreyImport Administrator Staff Member The Chief Contributing Member

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    Stage 1 complete
    Plug looks like it only made it in halfway but its threads arent damaged

    Stage 2 may be a little more challenging

    PXL_20221203_012202065 (Medium).jpg

    PXL_20221203_012225898 (Medium).jpg
     
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  4. ruckusman

    ruckusman White Mans Magic Master Premium Member Dirty Wheel Club

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    I'd say steel spark plug -v- aluminium cylinder head - the outcome might not be pretty for the cylinder head
     
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  5. Linkin

    Linkin The Mechanic Premium Member Contributing Member Dirty Wheel Club

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    On mine I was lucky, I was able to fit a new plug by making sure it caught the original thread and wound it in with hand tools - carefully.

    I think best thing to do is to chase the thread with the correct size tap, but set the engine so that the exhaust valves are open on that cylinder, then blow through the spark plug thread with compressed air and send any swarf straight out the exhaust.
     
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  6. maelstrom

    maelstrom LiteTek Staff Member Premium Member 250cc Vendor Contributing Member

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    Now that might work. Rather than jumping straight to a tap though, i suggest try making a chaser by grinding 3 flutes in the right size cap screw or bolt. It will remove less metal than a tap.
     
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  7. ruckusman

    ruckusman White Mans Magic Master Premium Member Dirty Wheel Club

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    Both excellent ideas, the tap and the bolt with the three flutes, I've done exactly that, just not with a spark plug hole - you could set that exhaust cam to open and with the exhaust removed put a vacuum cleaner on the exhaust outlet to suck anything loose out.
     
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  8. Murdo

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

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    Just put grease on the tap and remove and clean after every three turns, then regrease and continue. I would have a correct tap if you need it.
     
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  9. GreyImport

    GreyImport Administrator Staff Member The Chief Contributing Member

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    Thanx lads .... Ill venture down that yellow brick road in due course .... I do have a near new tap and die set on hand

    The headers practically fell off but the oil filter required a breaker bar .... go figure
    Filter was as expected and the headers and EXUP are in the refurb department ... at least the EXUP and all its components/cables are present

    PXL_20221203_084703302 (Medium).jpg

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    PXL_20221203_084256044 (Medium).jpg
     
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  10. maelstrom

    maelstrom LiteTek Staff Member Premium Member 250cc Vendor Contributing Member

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    Plug thread is a fine pitch and not usually found in kits, might get lucky.
     
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  11. GreyImport

    GreyImport Administrator Staff Member The Chief Contributing Member

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  12. KiwiMat

    KiwiMat Well-Known Member

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    Last edited: Dec 3, 2022
  13. ruckusman

    ruckusman White Mans Magic Master Premium Member Dirty Wheel Club

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    I just managed to get a full R6 exhaust for $100 for my YZF600 - 2010 I think - effectively close brand new condition, with the tail pipe and all.

    The muffler box which sits below the engine/suspension is going to be removed and a link pipe put in place, plus the link pipe between 2 & 3 needs to be lengthened so suit the centre cam tunnel.

    Got the idea from here
    http://fzronline.com/forum/viewtopic.php?t=9543
     
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  14. GreyImport

    GreyImport Administrator Staff Member The Chief Contributing Member

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    Yea I have that guy tagged in my ebay ..... first thing I need is a race tail :D

    Im going run everything stock to begin with until I know it does run 100%
     
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  15. maelstrom

    maelstrom LiteTek Staff Member Premium Member 250cc Vendor Contributing Member

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  16. GreyImport

    GreyImport Administrator Staff Member The Chief Contributing Member

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  17. thebeefsalad

    thebeefsalad Well-Known Member

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    Why not just butcher a plug to make a thread chaser? cut off the 'trode, knock out the porcelain, go nuts with the cutoff wheel and nearly lose a finger while trying to cut 3 slits into whats left of the plug. Drink a beer, runn'er home with the impact. Some advice, and something for laughs.
     
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  18. GreyImport

    GreyImport Administrator Staff Member The Chief Contributing Member

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    A little better

    PXL_20221204_053417022 (Medium).jpg

    PXL_20221204_053432883 (Medium).jpg
     
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  19. ruckusman

    ruckusman White Mans Magic Master Premium Member Dirty Wheel Club

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    Damn they look good and you got that done fast - out of interest, which paint?
    I remember I tried pot belly black on the FZR250 and it smoked like bejeezus and didn't last at all
     
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  20. GreyImport

    GreyImport Administrator Staff Member The Chief Contributing Member

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    @ruckusman

    This was so easy to apply and I did quite a few coats .... its supposed to be cured as well so I might stick them into the oven :D

    PXL_20221204_054755833 (Medium).jpg
     
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