Author Topic: Exhaust Studs (Read 36398 times)

Exupnut · « **Reply #50 on:** 04 February 2013, 09:21:28 pm »

nice one liam. glad ur on the road to recovery. i may pop round the weekend and see ow ur gettin on.

Dead Eye · « **Reply #51 on:** 04 February 2013, 10:06:19 pm »

You are more than welcome to help be break my back trying to lift the engine back in to the frame

To be honest, getting the engine re-seated is going to be the hardest part I think. Once its in, everything just bolts back together

red98 · « **Reply #52 on:** 05 February 2013, 06:54:59 am »

ohhhhhhhhhhhhhh.....i like the look of that impact stud extractor

not seen one of them before,thanks for sharing,helicoils are easy to fit and there`s plenty on the bay,have used several in my older bikes,there like a tightly wound spring that winds into an oversize hole which enables the orignal size bolt to be used....very handy

, good luck with the re-fit

Dead Eye · « **Reply #53 on:** 05 February 2013, 10:26:08 am »

Yeah, they came up in a few of my searches and worked a lot better than the other types I've seen (fixed size which wind against the stud). I have both types in my possession now and the latter ended up nearly sheering one of the studs. The impact ones were so much better and definitely recommended.

GrahamB · « **Reply #54 on:** 05 February 2013, 11:23:48 am »

£40 sounds fair to me for 2 studs removed & holes repaired, nice.

I have almost perfected the art of balancing my FZ engine on a trolley jack with a piece of wood between the 2 as a cushion. With one hand on the engine I just slowly jack it up with the other hand until 1 or 2 mounting holes line up then whack the bolts in sharpish. Probably better with extra pair of hands but you sound impatient.. . just like me! lol
Honestly I would love to give you a hand but checked you out on the map & you're too far from me.

Dead Eye · « **Reply #55 on:** 05 February 2013, 11:41:22 am »

Yeah, I thought £40 was pretty fair for 2 studs and it was done pretty fast. Dropped it off late Friday afternoon and picked it up early Monday afternoon and they aren't open over the weekends :P

I think I'll manage once I get the engine semi in to the frame. After that its a cake walk

Thanks for the offer of help as well ^^

red98 · « **Reply #56 on:** 05 February 2013, 01:10:07 pm »

good offer from EXUPNUT ........top man.........................just dont let him near you GLOVES OR KEYS

Exupnut · « **Reply #57 on:** 05 February 2013, 09:51:39 pm »

Dead Eye · « **Reply #58 on:** 09 February 2013, 08:30:49 pm »

Well after back breaking day or work and help from Expunut, we managed to get the bike re-assembled and fired-up

I've finally got nearly everything done to it at last

A quick question though - the new clutch cable is way too tight and I've slackened it as much as possible at the bar end. I've heard people talk about adjusting it behind the sprocket cover - how?

unfazed · « **Reply #59 on:** 09 February 2013, 09:16:08 pm »

Remove the rubber bung on the sprocket cover and you will see a 10mm lnut and a slotted bolt end for a screwdriver.
Loosen the nut, it will give a weird sound when it gives and then use a screwdriver to adjust it. You will need to turn it anticlockwise to slacken it.
When you have about 10mm freeplay at the lever tighten it up again and take up the final slack with the adjuster at the lever.

Exupnut · « **Reply #60 on:** 10 February 2013, 02:36:22 am »

dark times @ chelmsford....thank fuck for smart torch

the end of the day piccy...5 min after this the bike was purring like only a blue one can

Exupnut · « **Reply #61 on:** 10 February 2013, 02:39:21 am »

and what about the choke cable? was that new?

red98 · « **Reply #62 on:** 10 February 2013, 08:49:01 am »

nice work chaps

and not the warmest day of the year.....just odds and sods to do now then ?

Chris · « **Reply #63 on:** 10 February 2013, 11:00:54 am »

It's so blue it's tainted your photo

Gald you guys got it back together and running good

GrahamB · « **Reply #64 on:** 10 February 2013, 11:03:16 am »

Well done that man. Very pleased for you.

Dead Eye · « **Reply #65 on:** 13 February 2013, 10:07:54 pm »

So, we all know that i apparently lack any form of luck and once again this has been proven. I was going to go on my maiden voyage today but upon leaving it was instantly noticeable that the clutch wasn't engaging correctly. So i rode back home (only went about 1/4 of a mile) and stripped the clutch again. Find that i had two of the plates in the wrong order so put everything back and magically the clutch wouldn't engage at all. Tried adjusting the clutch cable constantly to no avail. So i got the old clutch cable back out and refitted it, but again no luck. Figured that maybe the springs weren't tight enough or something since they are only 10Nm as i was being careful. Went to tighten them and SNAP. The bit that the spring gets screwed into snapped from the clutch housing so my bike is buggered once again and I'm pretty pissed off with it. Almost at the point of breaking it and selling it for parts as nothing is going well at all.

Chris · « **Reply #66 on:** 13 February 2013, 10:13:35 pm »

Gutted Deadeye, such a shame when you've done so much already. Stick with it though buddy, it'll come good in the end and you'll appreciate it even more when it's running good

red98 · « **Reply #67 on:** 14 February 2013, 07:01:21 am »

bugger,bugger,bugger

after all that work

.....have a rest from it for a while,when you go back to it parhaps it wont be as bad

Exupnut · « **Reply #68 on:** 14 February 2013, 08:28:03 am »

When we put the clutch back together the last spacer we put was in proud by about half its width. U remember. Did we put in an extra spacer or friction plate by mistake? Shud a spacer go in first and last therefore enclosing all the friction plates?

Chris · « **Reply #69 on:** 14 February 2013, 09:01:19 am »

There was a good video on youtube of a guy replacing a fazer clutch, he went through what order they should all go in. Hope that helps...

Edit: found it -


Fazer Clutch Replacement

packie · « **Reply #70 on:** 14 February 2013, 09:46:25 am »

Stick with it, mate. I was in that frame of mind at Xmas. Was going to sell my bike off to the breakers and take a serious hit finanially. But I stuck with it and things have gone right over the last month or two. Outside a new front sprocket nut, I have had about 1,000 trouble free miles now over the last 5-6 weeks. This was the list of problems I had in the space of about 6 weeks which costed quite a few bob to sort out.........

I had an electrical problem at take off that threw me from the bike the first time it kicked in. Took a while to find where it was coming from and sort.
Then my camchain was knackered & the previous owner welded a blob of metal onto the tensioner to take up the slack so I had to buy a tensioner as well. Costed about £200
Then one of my fork legs needed to be replaced. Costed £75
My front & rear discs had to be replaced as I didn't bring a gauge to measure them when I bought the bike. Of course, I had to get new pads too to run with the new discs. Costed about £400
My back break calliper was half knackered and I spotted a "thou" one and bought that. Costed £50
My back master cylinder was also butchered and replaced that and in the process, I cracked the mounting footrest plate and had to replace that. Costed £60
I have tight spots on the chain that i'm not happy about and bought a new chain and spocket set. I then discovered I have been riding with no sprocket nut for the last few months!! Costed £100
While I was at it, I treated myself to a K&N filter and a new slip on can. Costed £150

On the positive side, I made a huge contribution to the UK enconomy to get it back on its feet!!

red98 · « **Reply #71 on:** 14 February 2013, 09:53:35 am »

thanks for keeping the enconomy going PACKIE

... DEADEYE, if it makes you feel better go back and read my stuttering thread , still not fixed

......had many happy miles on this bike so i know its worth it......come the better weather and with a few outings with the london foccers under your tyres you`ll be able to look back at these dark days and have a chuckle to yourself...well worth the pain and effort

Dead Eye · « **Reply #72 on:** 14 February 2013, 12:37:43 pm »

@Exupnut - We had the right number of plates, just the there is a special friction plate with a larger internal diameter that slips of the judder spring - this was in the wrong order which is what caused that last plate to stick out further than it should have. I also sorted out that Choke issue as well

@Chris - Yep, used that video as a guide myself as I have it bookmarked. He failed to mention the special internal diameter friction plate though.

@Packie - Yeah... I have no intention of spending that much money :P My bank account is still suffering from buying the bike to start with. Going to buy the new parts which should be sub £100 in total *fingers crossed* In reality, the thoughts of breaking it and selling it were just because I was rather annoyed. I needed the bike to do a journey to Bristol this weekend so instead its going to cost me twice as much in fuel with the cage which is also acting up

@red98 - I don't think I could have survived what you've been through on that 600, BUT, having said that, you do have the thou to keep you entertained in the meantime. I on the other hand am still off of two wheels

red98 · « **Reply #73 on:** 14 February 2013, 01:14:24 pm »

had i not had the thou i think i would have sorted it by now

......do miss the 600 though......thinking the 6 is better than the thou

Dead Eye · « **Reply #74 on:** 14 February 2013, 04:40:35 pm »

Grr, if only deliveries were instantaneous

Its just soooo frustrating needing a part or a tool or something but having to wait for snail mail and typically it nearly always arrives on a Monday or Tuesday so you have to wait until the following SATURDAY before you get any bloody time to work on it. Then you find something else is wrong and need to wait for mail again etc etc... Drives me foccin insane! End up just sitting around twiddling my thumbs thinking of all the wasted time...