Author Topic: Engine Rebuild (Read 17685 times)

Dead Eye · « **on:** 28 March 2013, 01:09:59 pm »

So as most of you know, my previous Fazer sort of burnt to the ground. I am however thinking of bringing it back to life but before I start on anything I need to make sure that it is actually feasible.

Now the fire got hot enough to render the rear wheel complete mush so with that in mind, how is the swing arm and engine going to have faired? Is it possible for me to salvage the engine and rebuild it, or is it simply destroyed? I would love for it to be ok, as I can potter about in my newly finished garage (today!!) and methodically dismantle and repair the old engine in my sweet time as I have a running Fazer to ride despite its many small issues...

The work required doesn't bother me and I think I have the tools and knowledge to under-take the job so that's not an issue either.

So without further babbling, are there any technical foccers out there who can lend some advice?

Chris · « **Reply #1 on:** 28 March 2013, 01:18:30 pm »

Yay! Glad the garage is finished mate! Goodluck with the rebuild.

keep us posted!

Chris

Dead Eye · « **Reply #2 on:** 28 March 2013, 01:25:24 pm »

Well, all being well, I may end up starting a build thread and show the process from start to finish

Chris · « **Reply #3 on:** 28 March 2013, 01:28:13 pm »

Quote from: Dead Eye on 28 March 2013, 01:25:24 pm

Well, all being well, I may end up starting a build thread and show the process from start to finish

That'd be great, we may well have a projects section soon too

Chris

Lawrence · « **Reply #4 on:** 28 March 2013, 01:30:58 pm »

Quote from: Dead Eye on 28 March 2013, 01:25:24 pm

Well, all being well, I may end up starting a build thread and show the process from start to finish

Lots of photos please

Foxwood · « **Reply #5 on:** 28 March 2013, 01:38:29 pm »

Well as a basic metallurgic principle, anytime steels or alloys are heated (notably more than in day-to-day temperature changes) their strength qualities do change. How much is hard to say in this case. An idea of how much heat it has been exposed to can be found from heat coloring of the parts. For example if they have been colored bluish, it can suggest very high temperatures that may weaken alloys significantly.

Fazerider · « **Reply #6 on:** 28 March 2013, 01:40:25 pm »

If the fire was hot enough to soften the alloy of the rear wheel then I would definitely look for a new swing arm.
The engine, on the other hand, looks from the photos to have been far enough away from the most intense part of the fire to have survived. It is basically one big conductive lump, even if the sprocket and clutch covers have been heat damaged, the rest should be useable. Rubber parts such as gear shift and driveshaft seals may need replacing of course, but the main bulk of the motor stands a very good chance of being OK.

Dead Eye · « **Reply #7 on:** 28 March 2013, 01:56:28 pm »

These were my thoughts, but thought I'd would check first to see if there were any resident metallurgists hanging around ^^

Obviously parts that need to be replaced will be. I think the frame can be salvaged - though the grab rail literally disintegrated...

The forks will need a very good service but should also be fine so I think the majority of it should be ok. It's going to take a while mostly from a financial perspective in sourcing new replacement parts

Chris · « **Reply #8 on:** 28 March 2013, 04:14:53 pm »

Will be an awesome project though! Shame it's come around this way but it'll be great to tinker away with it all. Got any outlandish plans for it or going to try and stick it back to standard/standard+?

The obvious road of streetfightering it/making it a naked bike would save having to source/pay for a fairing etc and would let you put your own unique twist to the fazer theme, possibly cheaper in some aspects although it all depends what you upgrade/replace/have custom made.

Chris

Dead Eye · « **Reply #9 on:** 28 March 2013, 04:56:05 pm »

I may have it without fairings initially, but I will aim to get it back to almost stock bar the standard sort of mods we've all come to know and love ^^

First things first is making sure I have a frame, engine and wheels really :P

The worst bit is going to electronics. The wiring is completely fubar and I had to severe large chunks of wire when attempting to move it - so I will definitely be back for electronics help! Thankfully I have a second bike to follow if I get lost. Its a huge project and probably the largest I've considered undertaking, but being able to do it at my leisure, at home, whilst having another bike on the road does take the pressure off.

I've been wanting to change the cambelts and tensioner on my car, I have all the parts but I just haven't gotten around to it as I don't have another car whilst mine is off the road... I used to but that's a whole other story :P

simonm · « **Reply #10 on:** 28 March 2013, 05:21:37 pm »

Be a complete nutjob and shoehorn the engine in to a Caterham seven replica, and stuff a turbo or two on it too ;-)

Is it worth spending that much time on a bike/engine that's gonna be worth £1k or so ?

Just offering an alternative perspective and more options.

Have fun and definitely do some pics. I'd love to see the burn out pixs too.

Dead Eye · « **Reply #11 on:** 28 March 2013, 06:22:37 pm »

I'm not doing it for money, I'm doing it for me - both experience and the fun or it

I'll be doing nearly everything myself and hopefully I won't need to spend huge amounts but over the long term if I do sell the bike (very unlikely) I'd be lucky if I broke even on it and that's before you take in to account everything I spent before this all happened :P

Exupnut · « **Reply #12 on:** 28 March 2013, 07:11:11 pm »

You could swap it with bozboz. Its cleaner than his.

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dBfazer600 · « **Reply #13 on:** 28 March 2013, 07:45:24 pm »

Just trying to add a file and I is failing baddly

Dead Eye · « **Reply #14 on:** 28 March 2013, 08:01:00 pm »

What is the file?

Exupnut · « **Reply #15 on:** 28 March 2013, 09:23:52 pm »

A computer file is a block of arbitrary information, or resource for storing information, which is available to a computer program and is usually based on some kind of durable storage. A file is durable in the sense that it remains available for programs to use after the current program has finished. Computer files can be considered as the modern counterpart of paper documents which traditionally are kept in offices' and libraries' files, and this is the source of the term. A group of files used by the same program can be packed into one archive file.mate. ;-)

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Dead Eye · « **Reply #16 on:** 28 March 2013, 09:37:40 pm »

If I had asked "what is a file" then your response would be appropriate... I am well aware of what a file is - I was more interested in the file contents :p

dBfazer600 · « **Reply #17 on:** 28 March 2013, 09:50:53 pm »

Quote from: Dead Eye on 28 March 2013, 08:01:00 pm

What is the file?

Its a youtube clip that is a fazer rebuild


Yamaha FZS600 engine assembly and test drive after valve lapping

I Just figured it out

Ta Fellas

Daz

Chris · « **Reply #18 on:** 28 March 2013, 09:56:43 pm »

Great video

I expect a similar one from you Deadeye

Chris

dBfazer600 · « **Reply #19 on:** 28 March 2013, 10:02:56 pm »

Would like to know who this guy is. He says it took him 3 evenings to put it all back together, I is impressd.

Daz

Exupnut · « **Reply #20 on:** 28 March 2013, 10:12:10 pm »

File content for 600 riders

On most modern operating systems, files are organized into one-dimensional arrays of bytes. Like ur brain odo. Hehe. The format of a file is defined by its content since a file is solely a container for data, although, on some platforms, like the fzs6,the format is usually indicated by its filename extension, ie retarded.nob, specifying the rules for how the bytes must be organized and interpreted meaningfully.u nob For example, the bytes of a plain text file (.txt in Windows) are associated with either ASCII or UTF-8 characters, or USR-1 ( u shit rider number-1) while the bytes of image, video, and audio files are interpreted otherwise. Most file types also allocate a few bytes for metadata, which allows a file to carry some basic 600 fzs information about itself.

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Exupnut · « **Reply #21 on:** 28 March 2013, 10:12:14 pm »

2-1 hehe

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Dead Eye · « **Reply #22 on:** 28 March 2013, 11:40:57 pm »

Quote from: dBfazer600 on 28 March 2013, 09:50:53 pm

Quote from: Dead Eye on 28 March 2013, 08:01:00 pm
What is the file?

Its a youtube clip that is a fazer rebuild
I Just figured it out

Ta Fellas

Daz

Awesome find, I'll see what I can do when I get round to doing mine.

I need to get some rags / sheets to line the garage floor a bit and may even buy a cheap wooden table to do some of the work. First things first is some half decent weather so that I don't freeze and some spare time and money :p

If its not too bad tomorrow I may start on removing the engine from the frame. Most of the fiddly stuff has been done since the carbs were removed already which is something else I will need to buy

simonm · « **Reply #23 on:** 29 March 2013, 12:32:31 am »

Quote from: dBfazer600 on 28 March 2013, 09:50:53 pm

Quote from: Dead Eye on 28 March 2013, 08:01:00 pm
What is the file?

Its a youtube clip that is a fazer rebuild
I Just figured it out

Ta Fellas

Daz

Omfg. He is a goatee wearing god. I've liked his youtube video to show I respect his facial hair..... He seems pretty handy with an engine too.

God only knows what he was faffing with most of the time though.

Dead Eye · « **Reply #24 on:** 29 March 2013, 04:12:20 pm »

Well I was lucky enough to be graced with some sun today so figured I'd make a start

The wheels are missing and so is the centre stand along with several other bits so its been propped up on bricks for the past month at least.

Since the carbs were already off (as this was the job before the fire) it made the work load relatively light. The downside was the sheer amount of plastic and rubber than had melted and fused to things all over the place. Amazingly the K&N filter that was in the bike doesn't look in too bad nick, but its sort of stuck in half of the airbox so I can't get it out!

Naturally something had to go wrong and the bricks weren't exactly what I would call sturdy so this happened...

... but thankfully I think this may have been a blessing in disguise. With the bike on its side it meant I could manoeuvre the frame around the engine which is lighter and easier to move. I had also removed one of the forks (removed both in the end) and the handle bars, the remains of the airbox, the bar that holds the coils and fuel pump / filter etc

So after some fiddling I managed to get the frame and engine separated

At this point, believe it or not, it started snowing... so I called it a day and packed everything away and moved the frame / engine and bits in to the garage