Thanks BB... ( i didn't think to look at Fowlers/MSP... Doh  )  Glad someone is on the ball... lol

Today... not a lot... It's actually snowing in the Dordogne ... but I did manage to get out last week...      (don't know whether the pics loaded???).

I have recently put some S21's on... (Surprised that they do them in Fazer600 sizes).. Waaaay OTT .. but they are FUN....  I've had to take the crash bungs off... but the tyres seem nice and predicatable.... Typically Bridgestone....


When I was commuting... 020's.. 021's (fronts were awful not a patch on the 020's).. Avon Storms were nice to ride on.. plenty of wet weather grip and lasted well...


I've got 023's on the FJR... they are fantastic... better than the T30's I had on previously...

Thanks everyone.. I worked through all your suggestions over the past 2 days...
I think that i found the answer.... Whilst doing a spanner check putting the bike back together i noticed that the expansion tank was empty.... no probs.. the tank was off anyway... took off the radiator cap and started filling it.... "blimey its taking a lot of mix".... as fast as I was filling.. it was peeing out of a hole (slit) in the pipe joining the radiator to the oil filter heater.... no wonder the engine was extremely hot when i got it home the other day... there was NO mix in the system at all !!!!!! All credit to the build quality that it didn't go pop at some stage out on the ride.... new hose from local bike shop....
will start it tomorrow just to see if anything has warped or blown..

2003 coil connection... just running through the list of jobs peeps gave for my other post....  as an aside.. i noticed the coil connections.... looking from above... facing the front of the bike.... my connectors are.... Left hand coil... Orange.. Red & Black.... Right hand coil.... Red & Black... Grey.... Just wanted to check that this is the correct way round please? Many thanks

Hi FazerSharp... Under the seat cowl the seat is cut away... bit like a Transit now..   LOL... It clips underneath across the brace at the rear and I've fitted a lock which connects to a brace I concocted at the front of the cowl.. a bit Heath Robinson.. but it's worked for years... Along with the high level can (originally a LeoVince.... I was wearing through the original on the front lip) the seat cowl was one of the first mods to be done.
Deefer did his all in one rear end and did the spraying... and I've mounted integrated indicators to the rear lights... standard rear mudguard, but cut away around the old indicator mounts.... that's it really for the rear end...
Nearly forgot... I fitted an old tank bag that zips on and off to the cowl like an enduro back pack... it was just to throw a few bits in whilst I commuted.... not a fan of wearing a rucksack.... The base is just bolted to the cowl...

Thanks Gnasher & BBBrown... Great advice.... I'll work through your suggestions....
The bike rebuild was started about 8 years ago... supposedly to ... one.. give it a refresh @ 38k miles.. new bearings etc... and secondly to protect it through winter commutes... powdercoating of aluminium parts etc.... I moved 7 times in those 8 years.. sometimes without a suitable work space... hence the delay.. LOL... Finished it last year, but the carbs had been laying around off the bike for that amount of time.. so I took the precaution to have them rebuilt... along with the calipers ... Retired now.. so the bike is only used for pleasure...   A couple of pics attached to show the results...

In the end I fitted a GTP .... LCD screen version... its ok.. fitted OK..  looks nice... but it no where near as accurate as the Healtech on the FJR.... THE GTP seems to need about 3k rpm to register the correct gear.... ive tried resetting it several times at low rpm.... but to no avail.... not a major problem... the bike is used for fun now... no commuting..

Hi B1k... the calipers were painted by the company that did all the refurbishment on them.... Brakemasters over in Chesterfield.... to quote their literature... "We use a tough heat-resistant, colour-fast solvent based coating which we oven harden before assembly"...... The bike hasn't done many miles since I finished.. so can't really say how well they will cope with use etc...

Pics of the powder coated items.....

2003 Yamaha FZS600 Fazer Rebuild

The original purpose for the work was to protect the ali during winter commute duties….. But that was 8 years ago…. !!!!!  I’m semi-retired now… the furthest I commute now is from the bedroom to the kitchen for breakfast….. 😊 So, although the bike isn’t a ‘show’ bike by any stretch of the imagination, it has a different purpose in life now…..

New/refurbished items:

• £700 worth of Seals, bearings and shims!!!!!!
• Forks rebuilt with Hagon Progressive springs
• New Delkevik Radiator
• Beowulf Guard
• New SS downpipes (quite why I didn’t just strip the originals I don’t know!!!!)
• Lextek carbon can
• Leovince hi-level link pipe reworked to fit can
• Calipers refurbished with new pistons, seals and nipples etc (Brakemasters Chesterfield)
• Carbs stripped and refurbished  (Matt Harper near Nantwich)
• New Inlet rubbers (engine side)
• Wheels painted
• Valve clearances whilst engine out of frame
• Hagon rear Shox
• ‘Fazer’ polished Torque arm
• Chain and Sprockets
• Clutch cable
• R&G Bar ends
• New fluids and grease all around
• MX Hand guards

Powdercoating:

• Forks
• Swingarm
• Cam covers and end caps
• Hangers and pegs

Exhaust hanger:

•   Rear Brake lever

Rear Brake caliper hanger:

• Gear lever
• Sidestand
• Main stand
• Cut down Leovince Can (Didn’t use in the end)
• Various other bits and pieces  (I’ll try and post some pictures)

£150 for all the bits at Rugby Powdercoating… But that was 8 years ago…… lol

The seat cover was already on the bike, but I attached an old tank bag to it… al la endure style… originally just to hold a few things on the commute….. Deefer did most of the extra curriculum ‘red’ paintwork before the ‘rebuild’…. I did the mirrors and fairing inners….

Pictures:

• Mark 1... Standard... save for a Givi Wing Rack....
• Mark 2... Seat cover and high level can
• Mark 3... Start of the redness.....
• Mark 4... todays iteration

[cleaned up the broken formatting, the post as unreadable - bkd.]

Taxed... insured... and MOT'd..... 

I cant even get back into the original post... i get the error message....The post in question is in the FZS600 forum... "She lives..."
screen grab below