The BozBoz Build

[bozboz]

Hi everyone, been a while since I've posted on here properly. Alot has happened over the last month -mainly getting a job in a gym, so no more despatching on my turd fazer!(so no more corrugated plastic fairing with drain pipe mount!)
So given that I can start cycling to work soon I'm going to start my bike rebuild. Theres a number of problems that I need to address quickly and a few mods I'd like to do to make it a better ride. Oh and before anyone says buy a thou -I am still an all weather biker so I'd like to keep the 600 for the winter months even after I do get a fazer thou/fireblade/ducati/who knows!
Ive got a few mods to do too such as K&N, upgraded front/rear suspension, foxeye conversion, paintjob, light engine tune....
So current problems that need doing:
Engine oil 10k miles old!
Fuel leak from pump
Rear shock has dumped all its oil (mattress bike)
Cam chain maybe 1 click away now
Leaking front forks(replaced seals and new stancions fitted)
Sprocket bearing badly worn (new bearing waiting)(new one now fitted)
Headlight wiring has a ghost(the ghost is back....)
No radiator fan (Summers coming!)(fitted)
No main stand(meh...)
Bent front fairing brace(foxeye fitted)
Frankenstein fairing(in the bin replaced by foxeye fairing)
Exhaust can blowing round crap rivets(yeah....still blowing...)
Rev counter sticks on 5k
Fuel guage KIA
Overheating light shorts when wet!
 
Parts I have aquired so far:
Fazer thou rear shock (Now fitted with Hyper Pro spring)
Fazer foxeye tank (Fitted)
Fazer foxeye fairing & brace (fitted)
Fazer foxeye headlight & loom (fitted)
Thundercat forks/yokes/fender (watch this space!)
Fazer foxeye main loom
Foxeye clocks
Rad fan (fitted)
Silicone rad pipes(now fitted)
Ill probably do some of the more simple things now but cant do a full strip down yet as I'll be going to france soon for a bike trip to a number of the WW1 graves with my dad and his pristine BMW 1150! Also who wants to spend the summer rebuilding a bike to ride in the stinking winter!(been on the trip -awesome great memories and no break downs!!!)
 
Oh and finally -Christo I washed my bike and have the pics to prove it!!!
 

[Dead Eye]

Yay, a build thread Looking forward to watching this ^^

[Chris]

Looking forward to this one, mind and put in plenty of pics for us 
 
Chris

[humbucker88]

If you figure out how to fix the tacho sticking at 5k, i'd be grateful if you let me know =) I'm presuming it's a dodgy connection which puts the tacho in TPS position mode but I've not been able to fix mine.

[caretaker]

and you'll be needing the trx850 rear caliper conversion as well. just so happens i have one for sale!!

[ChristoT]

Oh and finally -Christo I washed my bike and have the pics to prove it!!!

OK, then, waiting... 

[bozboz]

and you'll be needing the trx850 rear caliper conversion as well. just so happens i have one for sale!!

Already got a fazer thou rear caliper fitted 
Progress so far...oil change done! On a course for a couple of days so will be doing a big bite of it at the weekend! Pictures coming!

[bozboz]

Update!
Ive made some progress today! Ive fitted the hyper Pro 600 spring to the fazer thou shock and that is now fitted to the bike. Ive also changed all the rear wheel bearings and sprocket carrier bearing. I will start on the front suspension on thursday. Heres some pics...

[bozboz]

[Chris]

nice one, looks great!   

[Punkstig]

I just swapped my front end to a thundercat one, but atm still using fazer bars (just drilled 2 holes in the T'cat yoke!) at the weekend I'll put the T'cat bars on and see how they feel and if there's space for turning the bars.
Looking at it all I think I may have to use the T'cat brake and master cylinder for clearance around clocks!


You will need to make either new wheel spacers for both sides or cut up a standard one and add it to both sides, non speedo side needs a longer one than speedo side. (About 1.5mm on speedo side) not sure on other as I'm currently using a slightly hollow nut! 


Forks are a different length, so make some measurements, they will stick out quite a distance from the top yoke,
Thundercat fork travel is 5.1 inch 310mm but if you have this as a minimum you still raise the front by 25mm 
I've been risking it so far only allowing for about 300mm between the top of the fork lowers and the lower yoke, in theory under heavy breaking this would mean they will hit one another, I've not attempted extreme breaking yet but pre-load is at line 2.


I also put handlebar risers on to give clearance for the brake banjo against the right fork!


It is easy to do, just time consuming, front feels a shit load nicer now, personally I'm looking at a trx850/ fzr600 front wheel so I can have a 120/60 front tyre!

[kebab19]

The TRX front wheel conversion wont happen easily as the speedo drive thingy is different (size & design).
Frustratingly, the FZS600 has a unique drive setup which restricts a lot of interchangeable front-end Yam parts that would otherwise fit easily.

[Punkstig]

Ok, it appears my past investigations have been mistaken- followed a 'direct swap without mods' list, which appears to be incorrect, grrr

[bozboz]

Cheers for the info punkstig. Certainly not my first front end mod on for a bike but I think ill just change the seals on the standard forks and do the thudercat swap after the trip. Ive also ordered a pipercross filter, thought I'd give it a go as I've used K&N filters for all my other bikes and would like to see what the pipercross is like!
Things todo before I leave: Both tyres, front pads, clean front pistons, front fork seals/oil, clean/lube chain, change ehaust and lose the zorst wrap(what a load of sh!t)

[Punkstig]

No probs, part of the travel issue Is the lower yokes on the thundercat aren't flat, they bend down giving less travel distance, I'm tempted to grind it down as it would give another 5-10mm of travel space!

[kebab19]

I'm basing the TRX/T'cat wheel thing on someone who came to my garage a few years back for a front TRX wheel I was selling. He also thought it would fit but started muttering when he saw the drive mechanism built into the TRX wheel & said it wasnt the same as his Fazer's setup.

Having said that, it could perhaps be modified to fit? I believe Fazer / T'Cat / TRX wheel bearing dimensions are all the same, so a swapover not out of the question

[Punkstig]

Yeah,  as I've put the T'cat front end on already I'm going to see what the challenge is for modifying the tcat front wheel, I have a buckled front in the attic anyway so might as well hack away at that to see feasibility in modifying it for the speedo!


If its a goer I shall let all know!

[bozboz]

Right I'm bringing this thread back from the dead as I've been away from posting for too long (had alot on my plate over these last few months) Will now have a bit more time on my hands so its gota be done

Currently Its still very much a frankenstein bike with a red foxeye front fairing, blue foxeye tank and black rear. I'm going down the lines of a black bike still but now thinking of going abit crazy and doing a monster energy themed bike. Jobs to do this weekend will to sort out the headlight wiring as I do believe the wires are melted due to no relays in place!

Watch this space.

[Punkstig]

Update for you- I have the speedo working with the thundercat wheel.
Just needed to remove the wheel rubber seal and metal ring spacers,
I got hold of a fazer speedo sensor with the plastic top glued to the ceramic inner, ground down the drive tabs a little bit and fitted into the wheel with the spacers and rubber seal holding it in.

[Punkstig]

Wheel without seal or spacers- perfect already for the drive lugs!

[Punkstig]

Held in place, just means a little extra work come tyre fitting time!