Date: 29-11-21  Time: 06:33 am

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Topics - MFD

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FZS600 Fazer / FZS600 fork variations
« on: 05 December 2020, 06:27:46 pm »

Does anyone have full parts diagrams for the different forks used by the FZS600 over the years, or can shed some light on exactly what changed and what is interchangable between them?

I bought some cheap "2002" forks to test my bike after crashing it and severely bending the forks a month or so ago. Unlike the ones that came on my (2003) bike, they have a simple cap at the top rather than preload adjusters, but everything I've found suggests preload adjusters were added in the 2000 model. They've also got an excessive gap between the ends where the front wheel fits, so the axle draws them together by a few millimeters when tightened (the stanchions are straight) - is this normal?


For Sale & Wanted / WANTED: 2003 FZS 600 front forks
« on: 15 November 2020, 02:29:24 pm »
I'm after some forks to rebuild my FZS 600 after losing it on some mud and crashing a few weeks ago.

I just want to put them on for a few test runs before committing to repairing the bike properly, so they can be pitted and leaky, so long as they're straight. Honestly pitted and leaky would be best since I'll rebuild them with new fork tubes if the frame still rides ok.


FZS600 Fazer / Frame measurement after a crash
« on: 30 October 2020, 09:39:37 pm »
Evening all,

I had an accident earlier this week - came around a left hander at (I guess) 40-50mph during some heavy rain and hit a layer of mud on the road, both wheels immediately let go and the bike dropped onto the left hand side and started to slide, then something upset it (I'm guessing it hit a cats eye), and it flipped over onto the right hand side, throwing me off to slide along the right hand gutter while the bike shot off ahead, bounced off the dirt verge and came to a halt back in the left hand lane.

Luckily there was noone coming the other way at that moment, so after a few seconds sliding down the road on my back I got back up without any serious injuries (just a few bruises seemingly), but the bike didn't get off so well. The left hand fork tube is *very* bent, the fairing got bent around sideways and several mounting tabs broken off, the instrument mounting bracket bent, left hand pillion footpeg and silencer bent into the frame until it popped off, both wing mirrors disintegrated (I only found the remains of one) and various other minor scuffs/breaks.

Right after the accident someone in a Tesco's delivery van stopped to help me up and make sure I was fine, then a builder with an empty trailer stopped and offered to take me home. People *can* be nice sometimes!

So here I am with a very broken Fazer in the garage now...

I've removed most of the bodywork, fuel tank, instruments, etc so I can get a good look at the frame and hopefully confirm all the geometry is still ok before starting repairs.

Can anyone advise particular things to check/measure on the frame, correct dimensions/tolerances or methods? Any help greatly appreciated as I've never done this before.

FZS600 Fazer / Infrequent cutting out and magical recovery
« on: 30 July 2019, 07:08:59 pm »
Hello all,

After 18 months of (almost) flawless service, my FZS600 has decided to start impersonating my old Suzuki.

On the way home from work on Wednesday last week, while going up a hill, the engine just cut out with no warning, wasn't even trying to fire. After pulling over onto the pavement and turning it off/on a couple of times, it still wouldn't restart. After a couple of minutes of me taking my gear off I gave it another try, and it immediately fired on the first spin.

Fast forward to tonight, and it packed in not too far from home, same as before. Rode it down probably from 70ish to 20ish in gear, no life from the engine at all. Pushed it on a bit, still wouldn't start, pushed it on a bit more, still wouldn't start... until I was in sight of home.

There was no smell of fuel when cranking either time, and it didn't start with an almighty backfire like other times I've flooded in the past, so I'm inclined to believe its a fuel issue. Both times the fuel pump was silent for all the starting attempts, so I don't think it temporarily ran dry or was struggling to prime or anything like that.

Is there anything near the carbs that can shut off the fuel supply to all 4 cylinders, or am I barking up the wrong tree? Any other likely suspects?


FZS600 Fazer / Broken speedo drive and worn wheel bearings
« on: 26 November 2018, 07:17:55 pm »
Evening all,

For the past couple of weeks I've had an intermittent squeak from the front of my 2003 FZS600, I thought it was just the calipers binding again as they've not had a proper strip down in my ownership. It got bad enough this morning that I could hear it when riding along at low-ish speeds, rather than just when in traffic as previously, then around ~40 on the way home this evening.

Took the front pads off tonight... still something rubbing on the wheel.

Took the wheel off... the lugs on the inner sleeve of the speedo drive were broken off and the whole thing was rather dry and smelling a bit burnt. I don't think it was lined up properly when I had the tyre replaced a few weeks ago, so the lugs broke off, but jammed in place so as to keep it turning, and put sufficient force on it to cook the grease away.


Also both front wheel bearings have got a bit of a notch in them despite looking new, unsure if the sideways load from the wedged speedo drive could've caused that, or just normal wear.

Does anyone have the numbers for the right hand front wheel bearing and seal (couldn't read that side)? I'm going to drop by a bearing shop tomorrow to see if they can get me a replacement set.

I'm going to see if I can get the broken bits pegged back on, but failing that, does anyone happen to have a speedo drive assembly (or even just the inner sleeve) lying around?


EDIT: Took a picture of the thing

FZS600 Fazer / Chaaaaiiiiin
« on: 26 July 2018, 08:54:29 pm »
Just did a (too) quick adjustment of my chain, took it out for a test run around the block and when I got back it was hot to touch (goes tight-slack-tight-slack as the wheel turns) :eek

Its too unevenly worn to get in spec through its full rotation, so I'm looking at ordering a DID 530VX chain, but DID don't make split links for them. Last time I tried fitting a rivet link (on a DID 520 or 525VX), the head of the rivet failed and sheared sideways before mushrooming out to the expected diameter, I'm not sure if it was bad luck and I got a faulty link, the budget chain riveter I was using, or somehow my technique. Luckily a local shop had a split link for it.

Has anyone else had a chain rivet fail using one of the budget tools? I don't really want to spend £100+ on a professional riveting tool, but if thats what it takes...

Alternatively I could relive my 125 days and get a plain chain without any kind of seals...

General / Tool storage
« on: 07 April 2018, 01:32:14 pm »
Thought I'd sort out a tool kit to keep on the Fazer today, so got out the kit I used to carry under the seat on my old GS500 and...

The tray under the seat of the GS was pretty bad; it'd end up with water and dirt from the road under it sometimes. So the tools were wrapped in plastic bags (which wore through) and then a rag, which mostly kept water /in/ rather than out from the looks of it.

The fazer under-seat tray looks clean, so hopefully I'm already ahead, but any bright ideas on bags/etc for storing tools in which might actually keep them dry? Ideally ones which could keep a thin mist of oil inside them too.


FZS600 Fazer / Checked under my sprocket cover today... what is this?
« on: 22 March 2018, 02:29:22 pm »
So I finally got round to taking the sprocket cover off to check the nut today, and I've not seen a sprocket like this before.

It looks like some kind of plastic or resin was moulded around the sprocket, going out so far that the remaining parts touch the chain side plates. What weirdness have I stumbled onto?

I've also got the old 9mm thick nut, which I've read should be upgraded to a 12mm thick one, but there's only ~1mm of thread exposed on  the end of the output shaft. Do I need to change more than just the nut and locktab?


For Sale & Wanted / For sale: Suzuki GS500
« on: 19 February 2018, 04:11:15 pm »
For sale a 2005 Suzuki GS500, selling because I got the Fazer.

The frame could do with some paint in places and there are multiple cosmetic knocks from a previous life as a school bike, but goes/stops fine and will get you where you want to go. There's a rattle from the engine which is most noticable at tickover, I'm 99% sure this is just camshaft endfloat, as these engines are prone to.

Has recently had a new battery and the tyres/pads/chain/sprockets have plenty of life left in them.

Comes with two keys, service history and MOT until mid-June.

I have a Haynes manual for it and a new oil filter which I will throw in if the buyer wants them.

Milage is 50k.

Bike is in West End, Southampton.

Offers in the region of £650 please.

FZS600 Fazer / New toy
« on: 22 January 2018, 03:21:51 pm »
Per my thread in the introduction forum, I got myself a shiny new FZS600 the other day :)

This afternoon's job was taking the center stand off and starting to tidy up the frame around its mounting brackets:
I'm after a rear hugger for it, but out of the several on eBay I'm not sure which to go for. From squinting at the photographs in the listings, I think this one made by P&P Motorcycle Bodywork has the most coverage of the wheel and chain, but is that what I should be looking for?


The Laboratory ! / test
« on: 21 January 2018, 03:26:04 pm »

Introduction / New FZS600 owner
« on: 20 January 2018, 11:49:36 pm »
Hello all

I just got my own FZS600 (2003 model) to replace my gradually disintegrating GS500 after borrowing one for a week or so last year :D

Sadly I can't actually ride it yet, as I need to make a custom seat to properly support my fragile little arse, BUUUT I can start to fettle and service it while I wait for the materials for that!

I haven't done a full fine-toothed-comb inspection yet, but from the outside it looks to have been pampered and spent all its life under cover. Very little service history, aside from an invoice from a garage which says the coolant was changed in 2016. Is there anything in particular I should make sure to check? I've been warned to check the sprocket nut is the later thicker type, as the earlier ones can work loose and wreck the output shaft.

This will be my commuter in all weather once its sorted, so I plan to fit a "fenda extenda" on the front mudguard and also a rear hugger on the back considering how much my GS has rotted over the past few years...

Any suggestions which rear hugger is best? I see several different manufacturers on eBay including Powerbronze, P&P Motorcycle Bodywork and Pyramid Plastics.


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