Project Fazer: The build thread

[ChristoT]

It'd be a far easier to understand project apart from the engine though...i'd say it is the weakest link here...i really hope it is an easy fix...fazer engines are such bullet proof little lumps so to see one with likely issues just worries me....but hey that's me....& you are you...so fingers crossed. :thumbup

Valves may need grinding, and replace piston rings: nothing major. The bores are fine, so I'll start with those. According to its last MOT (last year, admittedly), it had only done 68k miles!! Obviously, I'll have to cross check the dash to see what it currently is, but there's a good chance I'm sitting on a sub 100k miles engine. 

I've done my share of large projects (mechanical and otherwise - some have taken 3-4 years to see through) and the only advice I can give is to break it up in to small parts and prioritise. So first is the frame, suspension, brakes and other important parts for a fully working rolling chassis. Next is a running, stock, engine with no issues, then move on to the exhaust.

At this point, you want everything as close to stock and don't worry about the little details (like decals and body work etc). Lay a solid foundation. The reason for stock is that its a known quantity and should anything go wrong you have a lot of help to work out the issues. If you start messing with things, it gets awfully complicated awfully fast when trying to figure out what's wrong.

I'm up for helping with labour, but you seem to be interested in doing that yourself. Best of luck.

My plan is to work on what I can, when I can. So when I can (hopefully this week), I'll start work on checking and rebuilding the engine. Then in a fortnight, when the ZX has gone, I can look at fitting the new swingarm, and see what needs doing there in terms of spcers and offsets. Hopefully, the engine will be a short fix, and the swingarm won't be too horrific, so by then I can work on the exhaust - one of the more complex jobs for me. As I'm basing myself off the R1 rear end, I already have measurements there. That will also involve rear fairing modification to accomodate the final solution. Based on that, I may have to remove the airbox if I have to get creative with the rear shock. Once the rear end is done, I'll move forwards to the plumbing: bigger radiator, maybe? And possibly an independent oil cooler? The tank and pod filters are simple swaps (to install at least - tuning the carbs is another matter), the front end is an independent work package. Other things are minor detailling mods: rad guard and belly pan are simple bolt-ons. Only when everything else is done shall I start prep for the respray (to black, of course!), and worry about decals etc.

And did NO-ONE listen to the song in the beginning of the thread?!?  :lol :lol