Bikes, Hints'n'Tips > FZS600 Fazer

Boz Boz Build 2.0

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bozboz:
Hi all! I thought I'd catalogue how this bike build goes, hopefully it'll be as good of a bike as my last!

So currently I've got a piece of rust in bike form on a 99 plate frame, crap paint job and been left standing for too long but it starts... I've already bought a few bits they include a clean hpi 2003 frame with v5 in my name, this will get powder coated then ill transfer everything over. New old stock SS Micron headers and have a foxeye fairing and tank, the fairing is currently fitted to my soon to be sold vtr1000.

Plan is to transfer over everything to the fresh frame and make perfect slowly as I've too many projects and a house refurb to complete but this way I'll keep the missus happy!

Ideas for the new build is fit lighter wheels from an R1 and and R1 2008 USD front end which I've already got and have fit to my previous FZR1000 and current VTR. Powder coat everything eventually and get it wrapped or sprayed maybe matt black.

Current issues I've found:
Tank fuel overflow blocked, now fixed as its left outside in the rain!
Clutch cable was rock solid but now is supper loose and not disengaging the clutch -any ideas welcome! Clutch cable operates the bottom mechanical arm.
Coolant smells and is a bit foamy when bike running again ideas anyone?
Cylinders all run but 1/2 hot with 4 cokder and 3 coldest. Maybe need balance/ clean out. Idle is ok.
Haven't drained oil yet, hoping its not milkshake! Was going to do compression test first, is there a tester on ebay known to work on the spark thread that is reliable?

Jobs this week are to get frame powder coated and hopefully start the strip down. Pics to follow!

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StreetFzr:
With regard to the cylinders running hot, I’d check the carb runners as I’ve just done mine and it was getting quite hot and when I removed them two were cracked all the way though to the inside and one carb had been fitted incorrectly and was pushing the lip of the rubber over. If they suck air after the carb they will pull in unmetered oxygen and run lean, causing overheating.
Coolant would be worth replacing and seeing it it clears up!

bald_pig:
I'll be interested in seeing how you progress, I think you nabbed the Micron pipes I was eyeing up!


+1 for the fzs/vtr combo, I have both sitting here as well!

BBROWN1664:
Coolant foamy and smells when running combined with the running lumpy/cooler on #3&4 I would be looking at the head gasket.
If the coolant wasnt an issue, I would be looking at blocked jets on #3&4

As for the clutch, pop the cover by th eleft foot peg off and see if the rod is in there and not jammed as well as the cable mechanism.

bozboz:
Thanks for the replies and advice people. Good timing as I had a couple of hours today to do a few tests on the bike!

So all 4 cylinders are sparking so no problem there. I've run the carbs dry so will see internals when I start the strip down next weekend.

The clutch looks new, however the push rod and ball bearing were practically welded together and its no longer ball shape so have no idea whats happened there! Needless to say ill replace.

I've drained the oil too, this looked fine! No milkshake. I've still to drain the coolant so fingers crossed! I really don't want to do another head gasket on an engine again...

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