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Yamaha FZR400R - Restore'n'Rebuild (IMAGE HEAVY)

Discussion in 'Other Projects - Other Bikes (non 250's)' started by MashtX, Nov 15, 2014.

  1. Linkin

    Linkin The Apprentice Premium Member Dirty Wheel Club Contributing Member

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    Also remember that electricity is like a lazy worker, if it can **** off home without doing its job, it will. Even with just a coil, lead, cap and spark plug there's a limited amount of things that could be wrong:

    Dead/dying/faulty coil
    Damaged or old coil lead
    Damaged or old plug cap
    Damaged or faulty spark plug

    Not much more than that, electrically.

    The other thing is CARBS CARBS CARBS with these bloody fizzers

    Swap the jet housings with jets in place with cylinder 2. Remember the inner and outer 2 are different to each other, but you can swap inner jets to inner jets and outer jets to outer jets.

    You will get it sorted, just go through your troubleshooting steps slowly and carefully.
     
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  2. MashtX

    MashtX Well-Known Member

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    So ok, lets clear up something there because I had these same questions.

    Coils - Brand New Dynacoils.
    Lead - Brand New NGK Wire
    Caps - Brand New NGK Caps
    Plugs - Brand New NGK CR8E

    http://vid23.photobucket.com/albums/b388/Xander0070/MOV_08051.mp4

    Thats a spark test of the dodgy cylinder so I am almost 100% sure spark is NOT an issue :/
     
  3. maelstrom

    maelstrom LiteTek Staff Member Premium Member 250cc Vendor Contributing Member

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    What @Linkin means is swap 1 & 4 since they are on the same coil.
     
  4. Linkin

    Linkin The Apprentice Premium Member Dirty Wheel Club Contributing Member

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    Fair enough, new parts and all - but that doesn't always rule out a faulty/failing part.

    The other thing to do is get an actual coil tester. Not one of those inline spark plug tester jobs. It's a housing that you plug the coil into, and then earth the other end on the engine. Inside the housing is a sliding metal bit that connects to the earth, used to vary the length of the spark for testing purposes. It usually has a scale as well. The larger the distance, the more voltage is required for it to arc out and earth. Test a good cylinder and then the bad one. If that bad cylinder lead can't get the spark to reach as far as the good cylinders, you have narrowed the issue down to the lead or the coil.

    https://www.youtube.com/watch?feature=player_detailpage&v=PeGXQ0OTkvA#t=134
     
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  5. maelstrom

    maelstrom LiteTek Staff Member Premium Member 250cc Vendor Contributing Member

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    Sorry Mash, posted my reply without seeing yours.
     
  6. maelstrom

    maelstrom LiteTek Staff Member Premium Member 250cc Vendor Contributing Member

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    If you briefly put your hand over the throat of cylinder 3 with the engine running it will suck a great wad of fuel into the cylinder. It should then rev its face off on all cylinders.
     
  7. MashtX

    MashtX Well-Known Member

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    Something to look at, I'll switch the plug leads over next time I get a chance to rule it out.

    I don't have much money left to spend on this bike so I really am just using what I have for the moment.
     
  8. MashtX

    MashtX Well-Known Member

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    Oh ok so. That simple test prooved that you can never check TOO many times.

    @Linkin I did indeed swap the leads over, made no change sadly.

    However after putting them back to their correct position I tried what @maelstrom suggested. Which showed up something really weird, I was getting no fuel sucked through on that cylinder. All others pulled a good deal through when I tried it - so! Lets see why.

    Popped the carbies out and checked the fuel in Carby 4, about 50ml drained out not including the stuff that spilt (I am a little clumsy at times) and then opened the drain screw on Carby 3 aaaaaaand nothing. Nada. Zip.

    Fine ok then!

    Popped the bowls off to have a look and voila I can see that the gasket at some point has managed to get pinched and I can only assume was leaking fuel out because after I fixed it and put them back on..... IT WORKED!

    Now I have no idea why this worked, because I would swear black and blue that I checked that before I put the bowls back on but hey, I am human. I do think it was horribly cruel that the one cylinder that has caused me so much grief was the one I somehow magically failed at rebuilding....

    You guys are legends <3 I was almost ready for the good old Lighter'N'Jerry can.
     
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  9. Linkin

    Linkin The Apprentice Premium Member Dirty Wheel Club Contributing Member

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    Nice one! If there's not enough fuel in the bowl due to a leak there's nothing for the jets to pull into the cylinder :thumb_ups:
     
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  10. MashtX

    MashtX Well-Known Member

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    BWahahaha.

    Smokey as all get out for now, but damn... it works!
     
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  11. maelstrom

    maelstrom LiteTek Staff Member Premium Member 250cc Vendor Contributing Member

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    Good news. To err is human. Much as we like to get worked up over mechanical things, it is almost always us that have made the mistake. Just a matter of finding where we stuffed up.
    Since you have put new rings into used bores you are going to need to give it the beans. Don't do any running in nonsense.
    cheers
    Blair
     
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  12. MashtX

    MashtX Well-Known Member

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    Once again I am about to learn something haha.

    What do you mean by give it the beans? Bring her up to temperature and just give it a nice big handful up to redline a few times?
     
  13. Linkin

    Linkin The Apprentice Premium Member Dirty Wheel Club Contributing Member

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    That's right, no babying. Warm it up and ride it hard.
     
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  14. maelstrom

    maelstrom LiteTek Staff Member Premium Member 250cc Vendor Contributing Member

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  15. maelstrom

    maelstrom LiteTek Staff Member Premium Member 250cc Vendor Contributing Member

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    Good news that it is running on four and it will be interesting to see how it goes when you take it for a ride. Did you get needles with those emulsion tubes? My needles and emulsion tubes were not the best so I will have to do something about it once it is running. Also interesting to see if those coils make for easy starting.
    cheers
    Blair
     
  16. MashtX

    MashtX Well-Known Member

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    I actually didn't, the only place I could find original needles was this place in the UK and by then I had run out of money to spend on the poor girl - so that is a one day maybe item, either that or the jet/needle kit from Factory Pro if I do some more power modifications.

    I unfortunately need to do a fair bit more work before I take that wonderful first ride, I have to find some more fairing brackets - which are rarer than Hen's teeth and usually just as expensive.
    Then the fairings, then new tyres.

    Only then! Will it finally be ready to actually roll out of the garage under her own power :D
     
  17. maelstrom

    maelstrom LiteTek Staff Member Premium Member 250cc Vendor Contributing Member

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    Well if there is anything from the 3TJ1 that fits, let me know. There is almost nothing of the standards parts that I am using so lots of bits available.
     
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  18. Linkin

    Linkin The Apprentice Premium Member Dirty Wheel Club Contributing Member

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    I believe Keyster do complete kits for the FZR400R, the trouble is finding them. Motorcycle Spares Warehouse in melbourne stock 3LN1 and 3LN3/5 kits, but not the 400 ones as far as I can see.
     
  19. MashtX

    MashtX Well-Known Member

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    I'm curious about these as the only ones over ever seen as a full kit are the Chinese ones.

    Any links/info?
     
  20. Linkin

    Linkin The Apprentice Premium Member Dirty Wheel Club Contributing Member

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    The kits are $50 per carb, but you all brand everything for each one. Just none of the bits that connect the carbs up to each other.

    Example: http://www.motorcyclespareswarehous...oducts/k-1203yks-ky-carb-repair-and-parts-kit

    I bought the 3LN1 kits and used only the needles and emulsion tubes, and used LiteTek orings and gaskets.

    This was all I could really find with a quick google on the 400: http://www.nrp-carbs.co.uk/shop/index.php?route=product/category&path=35&page=31

    Try this search as well: http://www.nrp-carbs.co.uk/shop/index.php?route=product/search&keyword=fzr
     
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