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Project Joker's Angry Fizzer 400

Discussion in 'Other Projects - Other Bikes (non 250's)' started by Joker, Nov 4, 2016.

  1. kiffsta

    kiffsta Senior Member

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    Franchise opportunities #winning
     
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  2. GreyImport

    GreyImport Administrator Staff Member The Chief Contributing Member

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    You need at least 5 FZRs ..... 1 running and registered and the rest needing major repairs and/or in a billion pieces all over the shop floor , under the verandah and in the backyard + various other forlorn projects scattered everywhere.

    .... but youre well on your way :D
     
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  3. ruckusman

    ruckusman White Mans Magic Master Premium Member Dirty Wheel Club

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    FWIW, IIRC, I was reading about either FZR600 or YZF600 engine into FZR400 chassis swap that someone did and they attempted to keep the FZR400 Air Box. Result was the engine was basically strangled at approx 9K RPM because of the smaller airbox capacity and and breathing issues.
    I also believe the FZR400, FZR600 and YZF600 share quite a few engine dimension so parts are interchangeable or adaptable, such as 600 barrels, longer stroke cranks etc

    Lots of mods have been completed successfully which is good as you won't have to pioneer things and can basically follow others recipes if you decide you want more ZOOM
     
  4. ruckusman

    ruckusman White Mans Magic Master Premium Member Dirty Wheel Club

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    I just wish I had the space, but then again it's likely a good thing that I don't...
     
  5. Joker

    Joker See "about me" for contact details. Contributing Member

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    Well, spent a little time on the golden girl this evening. Still starts first go without much hesitation but the battery sounds like it won't last much longer (given the slow crank I am not filled with confidence).

    Replaced the grips which were degrading with a spare set I have, also the broken clutch lever with the spare 250 one I had (was exactly the same conveniently). I also had a closer look at what was going on at the EXUP and.... Helloooooo rattle. One of the cables had snapped clean off.

    14956588_10157679652135716_4635073237942520368_n.jpg

    Easy enough fixed but the thing was shaking all over the place. I also had another good listen to the engine, I'm going to pop the top end off and do the valve clearances and inspect the tensioner/cam chain just for peace of mind. I held down the EXUP valve so I could hear the engine better and it's not too bad but a little noisier than I would like so no harm in taking a look.

    Unfortunately for me, not overly excited about jumping on a plane again to sunny Perth tomorrow but how else would I fund my projects?
     
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  6. Joker

    Joker See "about me" for contact details. Contributing Member

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    Time for a brief update I think.

    Cam chain tensionser was good, about 50% of the way out. Feels pretty springy (moreso than the 250) so unsure if there is a problem there. Now I've replaced the EXUP cable to address the rattle down low I'll be able to hear it a bit more and determine if the chain really needs attention.

    15027697_10157712945300716_1058574902636540607_n.jpg

    Started digging a bit deeper and I didn't realise these bikes have a "cover" over the fuel tank!

    15027850_10157712945545716_5121960702493757871_n.jpg
    Pulled off the nose cone and am continuing to look at the body work. Quite a few repairs are needed so although the gold will look good for a while once I address I think she'll undergo a respray. I'm inclined to go with an electric blue with orange decals to suit the club colours but am yet to come up with a design.

    15078577_10157712945500716_4968989421655812200_n.jpg

    Carbies look pretty good... haven't pulled them out yet but apart from being very dusty I don't see any major signs that they need attenion. Will check the bowls when I pull 'em off though to double check.

    15078962_10157712945435716_7651990953656378399_n.jpg

    Next phase is to dig to the top end and check the valve clearances, once that is done she'll go back together for another start-up and if all good, I'll take her for a good ride to see what she's got on an unreg permit. From there I will either clubrego or start repairing fairings for the respray... see how it goes.
     
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  7. Joker

    Joker See "about me" for contact details. Contributing Member

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    Another update... still digging.

    Fairings rubbed back pretty well, although it uncovered quite a few fatigue cracks, chunks missing, patchwork from sanding before the crappy rattle can job... quite a few repairs to do. They are stamped 3EN1 so I'm pretty sure they're the OEM fairings.

    15094462_10157732321255716_1058618096095635848_n.jpg

    Wiring is a bit messy so will need to tidy up. Also one of the wires has been melted and hacked from the fuse box.. not sure what circuit that is but I'm sure with my new best buddy @MashtX we'll figure it all out :D

    15073499_10157732321745716_5925617867452567775_n.jpg

    15037067_10157732321630716_8313218879588584683_n.jpg
    15135776_10157732321700716_5421311822884969395_n.jpg

    2 of the rubbers are cracked and perishing. I think I'm going to try a "repair" to keep them going. I had this idea that sikaflex (the car silicone black stuff you can get) is quite awesome for sticking stuff together so I'm thinking I'll get an old bicycle tyre and "glue" a piece around the rubber. That should stop any air leaks and prolong the life a bit, at least giving me time to source some new ones (when I can afford them!).

    14955986_10157732321780716_8318327961271258607_n.jpg

    Some nice spares, rummanging through there's a dash, rear sets and front pegs, 2 coils, a CDI (that made be really happy), caliper and a few bits and bobs.

    15032763_10157732321430716_6458360678117997661_n.jpg

    Already used my JBweld on the engine cover, will sand back and paint at some stage.

    15027661_10157732321445716_8441466343670353770_n.jpg

    All up looking pretty good, have pulled the radiator off tonight and when I get time next I'll be popping the valve cover off to see what I find in the clearances. Here's hoping they're all in spec, it's a bum of a job that one. Terrible photo below (sorry my iphone is the worst phone ever invented) I wiped the front part but the whole thing is covered in dust and muck... don't know the last time it ever came off but this bike must have been ridden under all conditions. Wipes off pretty easily though so a good clean up and she'll look shiny again. Don't know how anyone can keep their bike in that sorta condition though!

    15027422_10157732320855716_8286021846651864530_n.jpg
     
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  8. MashtX

    MashtX Well-Known Member

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    I'm very much keen on coming to see this beauty! My Fizzer needs some friends of the 400 variety

    I think between @joker and I now, we have enough spares to last ages

    Also, I have some older carb rubbers but I think they aren't all cracked.
    I'll have a squiz and check for the club night!

    Sent from my HTC_0PJA10 using Tapatalk
     
  9. my67xr

    my67xr Bike Enthusiast Staff Member Premium Member Contributing Member

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    Sikaflex Urethane 227 or 252, same stuff i used on my intake manifold's and airbox rubber's

    Fuse's -
    Headlight, 15A, 2x Red W/Yellow stripe wire's
    Indicator's/signal, 10A 2x Brown wire's
    Ignition 10A, 2x Red w/White stripe wire's
    Fan 10A, 2x Red wire's

    I reckon it's the fan wiring that's been removed, but could be the main headlight fuse too
     
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  10. MashtX

    MashtX Well-Known Member

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    That's the conclusion we came to as well when I checked my spare harness

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  11. Joker

    Joker See "about me" for contact details. Contributing Member

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    Yes I agree it might be the fan, the fan did have a connection though so I'm not sure where the other end of the wire goes. Loom looks in good condition generally. Headlight worked fine prior to disassembly both low and high beam.
     
  12. Joker

    Joker See "about me" for contact details. Contributing Member

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    Good night with a club mate pulling her down to do the clearances. Don't know if it's good news or bad news but almost all the shims need changing. Suppose it's better to know that now. Compared to the 250, most still had at least some clearance which is a plus.

    It doesn't have the same TDC marker as the 250 does, after reading the manual and confirming with @MashtX the marker is the join in the casing. Conveniently 180 degrees around is another join which seems to make the process fine once you've figured that out.

    15094481_10157743819970716_1599635560127555409_n.jpg

    Here are my "working sheets". The aim is to find where the clearance is, it will be between a thickness that doesn't fit and one that does...

    15036163_10157743819985716_4628804870180065040_n.jpg 15094286_10157743819830716_8059601263939210422_n.jpg


    My summary sheet. The ? points are ones I'd like to change if I can but are not necessary because they're in spec. I'd rather have most of the valves on the looser side. All up, 2 I don't need to touch, 4 maybe's and the rest will need a smaller shim.

    15094487_10157743819000716_5802500368203825352_n.jpg
     
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  13. Joker

    Joker See "about me" for contact details. Contributing Member

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    So bit of a club gathering and @MashtX ensured the brothers finally meet...

    15193517_10157774182375716_6089704205551716070_n.jpg

    Carbies are pretty clean, we found the main jet is stock but the pilot jet is not standard and is quite large...

    15203154_10157774182060716_2237751252083344704_n.jpg

    Bit of burning gases probably leaked through onto the cams considering most of the valves were out of spec...

    15203243_10157774182580716_4166859777281520045_n.jpg

    And the timing lines up pretty well. Cam chain is not OEM as I found the pined pin on one of the rotation. All signs are pointing to a full engine rebuild at some stage of it's life... which is probably a good thing provided it was done properly.

    15253639_10157774182550716_6199882998501744227_n.jpg
     
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  14. my67xr

    my67xr Bike Enthusiast Staff Member Premium Member Contributing Member

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    Just interested, what size were the bigger pilot's ?
     
  15. MashtX

    MashtX Well-Known Member

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    Honestly not sure, as far as I can tell they aren't genuine Mikuni jets so the size markings didn't make any sense, for what markings we did see

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  16. GreyImport

    GreyImport Administrator Staff Member The Chief Contributing Member

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    Mikuni has their logo stamped on them

    MikuniEmblem1.jpg

    The pilot jet is down the hole .... and can be very hard to remove as the soft brass head can just crumble

    Jets.jpg

    pilot jet.jpg
     
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  17. Joker

    Joker See "about me" for contact details. Contributing Member

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    Pined pin...

    15242033_10157778069295716_4097432210568727092_n.jpg


    Carby pics

    15095513_10157778069560716_5932565735373466832_n.jpg

    15171050_10157778069065716_4250281717765385902_n.jpg

    Some are stamped, some arent - mains 86 and starter 52.5. Don't know how accurate that is or if they're all the same though.

    Bit of decoration for the southern Fizzer factory...

    15179098_10157778069160716_1567268471319314101_n.jpg

    On @my67xr's advice I went down to bunnings to check out plastic welding rods. Sure enough, tool section by the welding gear they have them. 3 different compounds but I luckily grabbed the last ABS one. $12 for the pack. I have experimented using an old fairing but there must be something that happens to the plastic over age as it goes all spongy and horrible. The welding rods are great, very pliable and the finish I can get is a million times better. Maybe if I use a fairing it needs to be newer than 20 years old...?

    15179020_10157778069615716_214932710285399644_n.jpg

    Started reconstructing one of the holders... worked out OK. Superglued a washer in place and built up plastic around it. Will need to carefully drill it out a bit but it will do the job, it's a lot more solid than I expected.

    15181611_10157778068985716_8626169434650831083_n.jpg 15181199_10157778068285716_2761432957262467101_n.jpg

    So all going good, thought I'd finish torquing up the cam caps... then....

    15230711_10157778069420716_1293578212034931193_n.jpg 15181267_10157778068990716_7709590711164955122_n.jpg

    Lost two of the bloody threads. One looks like it had a helicoil in it before which is a problem... don't know about the other. What a pain, all the others torqued up fine but these two...

    Absolute B!$CH of a place to get to as well with a drill for another coil (which I am praying will work in both instances) so will either need to drop the engine out or take the head off to fix.

    Still spewing... everything else was going so well but I guess setbacks are a part of life...
     
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    Last edited: Nov 27, 2016
  18. Jo Verhelst

    Jo Verhelst Forty2 Contributing Member

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  19. Joker

    Joker See "about me" for contact details. Contributing Member

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    Well I spoke to this great guy not far from me who seems to know all his cylinder head stuff so I guess a new head gasket is on the cards, but he thinks he has a few ways to tackle it. Might chat to him about the 250 as well while I'm at it. So until then I'm going to suffer from PMS big time... :(
     
  20. MashtX

    MashtX Well-Known Member

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    Le feck. That's insane... I have no idea how someone could pull those threads out, unless they were using a 1/2" breaker and a 200lb gorilla haha

    Hopefully this guy can sort you out, because that's a gigantic pain in the arse

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