Project Fazer: The build thread

[Deefer666]

He's a crazy french-man... before too long he'll be waving a white flag in his garage 

Having said that, he is also stubborn and illogical....

Ahh lets hope hes better at building bikes than his countrymen are at playing Rugby shall we? 

[ChristoT]

He's a crazy french-man... before too long he'll be waving a white flag in his garage 

Having said that, he is also stubborn and illogical....

Ahh lets hope hes better at building bikes than his countrymen are at playing Rugby shall we? 

Ahem.... 

[ChristoT]

Minor update time!

Had another wee go at the rear end today.

Well, the good news is that the gap looks to be only about 5mm!

The Fazer swingarm has two dust-cover-like things that sit over the needle bearing faces at each end of the arm. I measured the Bros arm minus these covers, so may be able to get away with a washer or two either side. Something to consider!

Unfortunately, setting up the suspension is going to be a bitch. There simply isn't enough room in there for a direct shock. There looks like there might be room for the shock with a linkage, so I now need to figure out how I'm going to attach dogbones to the Bros arm.

I also went round to Deefer's for a chat: the R1 tail unit is going to fit beautifully. It may require a little "persuasion" to fit the plastic round the metalwork, but it looks like it should be good. Then it's exhaust time!

Also, hopefully I'll start work on the engine this coming week. Watch this space! 

[mickvp]

Get some pics of ups the swing arm sits relative to the current suspension mounts so we can see what can be done

[ChristoT]

Get some pics of ups the swing arm sits relative to the current suspension mounts so we can see what can be done

All I did was stick a couple of bolts through the pivot points on the frame to position it roughly. Barely any space there.

I might get some pics up next weekend, when I have some time. I now need to also get some spacers made from case hardened steel, so hope that won't break then bank!

[mickvp]

Don't you mean you need to get some spacers made, and then case hardened?

What sort of size spacers do you need? Might be something I can help you with depending

[ChristoT]

You want your name on a fast (not blue) bike, don't you? 

The total space seems to be in the order of 5mm without dustcaps - so that would be 2x2.5mm spacers. I've ordered some callipers off ebay, and will do a proper job of measuring everything up either later this week or this weekend - stil minus dustcaps (need to source some)

Also had a proper measure: looks like the Bros arm is actually 40mm longer than the Fazer one, but it looks like it'll sit well. 

[mickvp]

If you let me know the id, and od of the spacer, I might be able to make a couple up for you

Might even get lucky and have something the right size laying about that we a
Ready currently make.

[Dead Eye]

Christo; have you taken any measurements relating to the offset of the rear sprocket compared to the front or even the stock? Will the sprocket even run on the same size chain as the stock Fazer? Ideally you need to take this into consideration before shelling out any cash making it fit. It's also prudent to check that the Bros swingarm will actually position the tyre centrally as you may find the spacers on each side actually need to be different sizes...

[ChristoT]

Christo; have you taken any measurements relating to the offset of the rear sprocket compared to the front or even the stock? Will the sprocket even run on the same size chain as the stock Fazer? Ideally you need to take this into consideration before shelling out any cash making it fit. It's also prudent to check that the Bros swingarm will actually position the tyre centrally as you may find the spacers on each side actually need to be different sizes...

I have had a look, and I am pretty sure that the sprocket will need extending outwards on the engine side. By how much, I don't know yet. Based on rough numbers obtained from the forum and my prodding so callipers at it roughly, looks like the offset will be about 5mm out.

Good point on the fit of the chain, I haven't checked yet, but will do so tomorrow.

I am assuming (dangerous, I know!) that the Bros pivot ends are symetrical as regards the wheel centreline. I'd be surprised if they weren't, but I will be sure to double check later this week.

EDIT: Bollocks. The Bros uses a 525 chain, and the FZS uses a 530. The length isn't a huge issue: the Fazer uses 110 links, and the Bros 112. And considering that I'm changing the pivot point, I may be able to get away with a stock chain. The question is whether I need a new rear sprocket modified from a stock Fazer one or even machined from new. 

[Dead Eye]

Still lots of unknowns - you need to take a ton of measurements to be certain about moving forward with this. Will be a waste of money to find out later down the road that it won't work. Guess work is quite a risk in this instance...

[JoeRock]

Christo; have you taken any measurements relating to the offset of the rear sprocket compared to the front or even the stock? Will the sprocket even run on the same size chain as the stock Fazer? Ideally you need to take this into consideration before shelling out any cash making it fit. It's also prudent to check that the Bros swingarm will actually position the tyre centrally as you may find the spacers on each side actually need to be different sizes...

I have had a look, and I am pretty sure that the sprocket will need extending outwards on the engine side. By how much, I don't know yet. Based on rough numbers obtained from the forum and my prodding so callipers at it roughly, looks like the offset will be about 5mm out.

Good point on the fit of the chain, I haven't checked yet, but will do so tomorrow.

I am assuming (dangerous, I know!) that the Bros pivot ends are symetrical as regards the wheel centreline. I'd be surprised if they weren't, but I will be sure to double check later this week.

EDIT: Bollocks. The Bros uses a 525 chain, and the FZS uses a 530. The length isn't a huge issue: the Fazer uses 110 links, and the Bros 112. And considering that I'm changing the pivot point, I may be able to get away with a stock chain. The question is whether I need a new rear sprocket modified from a stock Fazer one or even machined from new. 

First step is to make sure that the wheel is centred Christo, so measure to see if its centre in line with the swingarm, and if so that makes life a lot easier as you'll need equal size spacers to get it into the Fazer frame. Sounds like you'll also need some kind of collars manufacturer for the frame as well if the swingarm on the bros is smaller. Next stage is to do the sprocket, which might be more of an issue - you'll most probably have to get a custom one made to get it to the right spacing so it lines up with the fazer front sprocket, it's somewhat unlikely there'll be a sprocket already available that conveniently fits the bros wheel with the correct spacing (or even if there is, you'll have fun finding one!)

[red98]

Get the wheel and swingarm mocked up in the frame using whatever comes to hand...back wheel in line with front, two long pieces of angle iron would do it, if not a couple of chalk lines on the ground will do, ask the landlord first   ...sounds as if you will need to use spacers on the rear sprocket aswell.remember, with all the front sprocket nut issues you dont want to be using spacers here....sprockets have got to be spot on or you'll have all sorts of problems.....iam with deadeye here, dont spend any money unless your positive its going to work....and PICTURES, WE NEED PICTURES...with us all being experts on here we may spot something you've missed. ......final top tip...MEASURE TWICE, CUT ONCE.......good luck christo, it may not sound like it but iam on your side 

[lmdtm]

The whole one sided swingarm is cool and all, but how did you fit a Fazer in the back of a 106?? 

[mickvp]

you found bearings yet?

[ChristoT]

The whole one sided swingarm is cool and all, but how did you fit a Fazer in the back of a 106?? 

First time was after 2 Polish chaps helped me load it!

As for how I drove it - the engine was in a box on the passenger seat, with a corner of the box bashed in to allow me to get to 1st gear. My knees were round my ears as the seats were right forward, and the tailgate was held closed with string!! 

you found bearings yet?

About to have a recce. Ta for the link, BTW. 

[ChristoT]

Mini update!

On Tuesday, work started on the engine. Stripped out the clutch, and about to lay into the gearbox.

The clutch springs are shagged. Great. Also, the clutch plates are on their service limit. OK for engine testing, I guess, but I'll have to keep and eye on them. I had a slight scare with the gear selector arm, which put up a fight coming out. Luckily, it was just light corrrosion, and a quick scrub on the bench grinder sorted it out straight away.

Stripped out:

Details Fazer engine 1

Fazer engine 1

The bits!

Details Fazer engine 2

Fazer engine 2

In other news, I have also bought some engine bars (thanks, Apage16!), and I plan to integrate them into a bellypan when the engine goes back in the frame.

On the shopping list this month are the gaskets (ordered), the cam chain, uprated clutch springs, and I hope to start work in ernerst on the swingarm this weekend.

Stay tuned, campers! 

[noggythenog]

The whole one sided swingarm is cool and all, but how did you fit a Fazer in the back of a 106?? 

[size=78%]2 Polish chaps helped me load it![/size]

Who Doddsie & BBB?




Aw you mean guys from Poland 

[Dead Eye]

On the shopping list this month are the gaskets (ordered), the cam chain, uprated clutch springs, and I hope to start work in ernerst on the swingarm this weekend.

Stay tuned, campers! 

What springs have you bought? If you haven't yet, avoid the EBC Heavy Duty ones - they are too strong and just don't work properly with the Fazers clutch. I fell victim to this as have a few others on the forum

[Deefer666]

On the shopping list this month are the gaskets (ordered), the cam chain, uprated clutch springs, and I hope to start work in ernerst on the swingarm this weekend.

Stay tuned, campers! 

What springs have you bought? If you haven't yet, avoid the EBC Heavy Duty ones - they are too strong and just don't work properly with the Fazers clutch. I fell victim to this as have a few others on the forum

OK I know what happened, little know fact that the FZS600 has two different clutches fitted during its manufacture run, and it doesnt seem to matter what age the bike is. I have spoken to Yamaha UK about this and even they dont know why this is. There are two different clutch spring kits for the FZS600, I will dig out the part numbers.
 

[Dead Eye]

Well that would explain a few things :P Hadn't heard of anyone with success with the EBC springs so assumed they were at fault

[ChristoT]

Don't suppose you still have those barely used springs?

[midden]

Spacers behind the engine sprocket, maybe.

Have you seen the threads regarding The fzs600 front sprocket nut? 

[ChristoT]

Spacers behind the engine sprocket, maybe.

Have you seen the threads regarding The fzs600 front sprocket nut? 

Only a problem if it's over-torqued. A Talon sprocket should do the trick.

[midden]

I was thinking on basis of cure being thicker nut which uses all thread on the shaft, so spacers behind would effectively reduce the advantage of extra thread.


talon sprocket?