Date: 28-03-17  Time: 01:30 AM

Author Topic: Refitting exhaust FZS600  (Read 239 times)

brockman

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Refitting exhaust FZS600
« on: 14 March 2017, 07:08:11 PM »

Hey all,


So, I have a used Fazer in my garden that needs the exhaust refitting.  Problem is the engine studs are all shot to hell, and having tried everything to get them out it's looking like removing the engine & drilling them out!!


Apart from the above, the bike is fine - starts and everything.


Having never taken the engine out of a bike before, does anyone have any tips/gotchas before I start?  I've got the Haynes manual, a garage, and a friend with a penchant for fixing up old cars :)  I'm also going to need new gaskets for the head and for the exhaust headers - does anyone know a good place to buy from??


Will post pics as I go, waiting on garage space at the moment though...


Cheers!
 

Disorderlypunk

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Re: Refitting exhaust FZS600
« Reply #1 on: 14 March 2017, 08:41:28 PM »
exhaust gaskets £4-5 are all over ebay as are the studs £8ish
i have the exact same problem at the moment and while waiting for the new studs i have sprayed wd on studs everyday
have suffered in this area with smaler bikes with easier access so this is going to be an interesting one
make sure you use a anti sieze compound on the new studs
riding this that and the other
modifing everything...
vloggin some bits - http://www.youtube.com/channel/UCvWtJO9iyS8XsR9RNHx72UQ

Andy1970

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Re: Refitting exhaust FZS600
« Reply #2 on: 15 March 2017, 08:49:40 AM »
Regarding removing the engine, the Haynes manual states that you need to remove the oil filter. The only piece of additional advice I have is to remove the oil cooler as well. It is possible (just barely) to get the engine out without doing this, but it's a lot more difficult and you risk scratching the frame and damaging the threads on the oil filter mounting. Good luck.

bird

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Re: Refitting exhaust FZS600
« Reply #3 on: 15 March 2017, 03:42:16 PM »
I had the same problem with 2 studs. heated 'em with a gas burner and was able to unscrew them no prob!

Wookee

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Re: Refitting exhaust FZS600
« Reply #4 on: 18 March 2017, 02:00:37 PM »
I had the same problem with 2 studs. heated 'em with a gas burner and was able to unscrew them no prob!


Ditto.


I didn't even bother trying to get any of them off until I had soaked them in Plusgas for a few days then used a blowtorch. Funny enough they all came off dead easily 8)

Disorderlypunk

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Re: Refitting exhaust FZS600
« Reply #5 on: 18 March 2017, 07:51:15 PM »
good to hear plus gas and blowtorch works as thats my plan (day  4 of soaking)
riding this that and the other
modifing everything...
vloggin some bits - http://www.youtube.com/channel/UCvWtJO9iyS8XsR9RNHx72UQ

Disorderlypunk

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Re: Refitting exhaust FZS600
« Reply #6 on: 20 March 2017, 09:14:30 PM »
ok so nuts were in worse than expected condition no spanner / gator grip / maul grips would work
spliting chisel and lots of time to tap and split nuts only resulted in two broken studs
tommorow will be removing exhaust, moving rad and associated bits and left over studs
in house engineer (Father) will be drilling out broken studs without much issue as long as no more break



riding this that and the other
modifing everything...
vloggin some bits - http://www.youtube.com/channel/UCvWtJO9iyS8XsR9RNHx72UQ

tommyardin

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Re: Refitting exhaust FZS600
« Reply #7 on: 20 March 2017, 10:05:04 PM »
I had a  similar problem when I replaced my down pipes.
I had been soaking the studs in W/D for about 4 days before starting the job.

Two of the stud nuts come out bringing the studs with them, I managed to get 5 other nuts off but one sheared the stud, but as the others were all off I was able to remove the original down pipes.
The sheared stud was one of the centre (ish) studs and although it was sticking out of the head by a bout 6 or 7mm it was almost impossible to get at, I tried moles but once they were snapped into place the was no room to turn them.

I managed to get the broken stud out by using a small 5mm socket (1/4" drive) with a 1/4" to 3/8" adaptor and a short extension bar that allowed me get between the front duplex frame tubes and gently tap the 5 mm socket onto the the stud that was sticking out of the head.

I kept gently tapping the end of the extension bar and it forced the socket over the stud, actually moving the stud material to completely fill the socket then a ratchet on the end of the extension bar and just unscrewed the broken stud, I actually think that the tapping helped break any corrosion that was helping to hold the stud in place.
I never managed to get the broken stud out of the socket but it did the job.


Oh! my apology to darrsi for the re-writing the Gettysburg Address, but I thought it might be helpful.
tommy
« Last Edit: 20 March 2017, 10:11:21 PM by tommyardin »
Don't mess with the guy if the guy don't mess with you.

Disorderlypunk

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Re: Refitting exhaust FZS600
« Reply #8 on: 21 March 2017, 12:27:50 PM »
CRAP CRAP CRAP CRAP
5 of the 8 studs sheared heads got to come off now - was amazed how easy they snapped
tried all the tricks heat/flash freeze tap in with hammer to break seal - nothing worked
really didnt want to have to do head strip
and its harder on this than my 82 gsx1100
i knew i should have bought a bike lift
riding this that and the other
modifing everything...
vloggin some bits - http://www.youtube.com/channel/UCvWtJO9iyS8XsR9RNHx72UQ

fazersharp

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Re: Refitting exhaust FZS600
« Reply #9 on: 21 March 2017, 12:57:17 PM »
I know that my bike at 19 years old has over the last 17 years has only ever seen dry roads but stuff still gets rusty, last year I soaked my studs for about 3 months, every time I went out on it and came back I used a syringe with a long blunt needle to get right in and behind the collar I did it whilst still hot and then again when cold. I used something called Kroil which is used for cleaning and maintaining guns and is so called because it is a Kreeping oil (creeping )
They came off ok, but not sure if it has more to do with them being in good condition or if the oil used or the length of time soaking which was the biggest factor but I would recomend getting a syringe for targeted oiling and to do it for longer.   
« Last Edit: 21 March 2017, 12:59:53 PM by fazersharp »
I don't do rain or threat there of. dry rider only with no shame.