Removing FSZ600 Cylinder head with engine in Situ

[Dave48]

Thanks - ok will remove clips and leave the inlets where they are.

I've marked crank position as well as cam sprockets and chain position on them. So will try to put back as it is positioned now.  Then once it's all moving freely will double check the factory marks line up.

Never had a 4cyl bike engine in this many pieces so sorry for the stupid questions   many thanks for the help.

Its not stupid to ask advice-its sometimes stupid not to! :eek Good luck & let us know how you get on

[Craiginuk]

Thanks all, head off. Not pretty but could have been worse? Anyone have an inlet valve kicking about? I seem to have bent one. Or a number for Deefer please?

[ChristoT]

Thanks all, head off. Not pretty but could have been worse? Anyone have an inlet valve kicking about? I seem to have bent one. Or a number for Deefer please?

Deefer's number is 07887 854 614. 

[Craiginuk]

Thanks, that's the number i had too but it says incorrect number when i dial for some reason.

[ChristoT]

Thanks, that's the number i had too but it says incorrect number when i dial for some reason.

I get that too, but it's definitely his number. He switches his phone off after work, might have something to do with that. If all else fails, send him a PM. 

[Craiginuk]

Would inlet valves from a 2001 model fit a 1999 model?

[Dave48]

AFAIK the valve size hasn't changed between years so they should fit ok. Haynes gives all relevant specs/clearances.

[His Dudeness]

There's a parts manual for the 1999 model here http://foc-u.co.uk/index.php?action=down...ew;down=13

You can get the part number for the intake valve and do a search for it. You might get one cheap if you're lucky

[Red Ceri]

You can check all Yamaha parts for all years on the yamaha uk site here, http://www.yamaha-motor.eu/uk/services/o...index.aspx#
That'll let you know if the valves are common between years

[Craiginuk]

Thanks, looks like they are the same! Found some on ebay so hope to assemble in next week or so.

[Craiginuk]

Finally got head back together and on. Lapped all the valves too while i had it off.  But i'm having problems with the timing chain. When i tried to install tensioner it is tight even before i install spring. Did not want to force anything so slowly turned over on crank via magneto bolt. The engine bottom end turns over but cams aren't moving.


If i stick my finger against the guide where the tensioner should sit, i can feel the chain  or something moving i.e can feel something scraping. Is it possible the chain has come off the sprocket at the bottom?


Any ideas before i set fire to it?

[red98]

Could of done, either that or the chain has doubled up somewhere.take the tensioner out and "jiggle"  the chain to free it, dont force anything  .....dont worry about the chain moving on the bottom sprocket its the marks that are important,they have to be spot on, good luck 

[Craiginuk]

Thanks for all the help guys. Time to throw in the towel. It's jumped off the sprocket at the bottom and i don't have the time to sort it now. It'll be on ebay as a spares or repair as soon as I've re assembled it all back together. A shame because it is an otherwise mint bike.

[His Dudeness]

That seems a bit drastic. Did you try to get it back on?

[Craiginuk]

Yep tried but can't get it on. I have spent way too much time on this now. Need the space in garage  for car and have a lot of work travel coming up.  I guess it is drastic but i just want rid of it now.

[His Dudeness]

Is it off the sprocket and bound up or is it off the sprocket and free? Could it be on the sprocket but kinked?

[Craiginuk]

It's off the sprocket and free. Just feels like it is turning on crank journal or smooth shaft.

[His Dudeness]

Hasn't happened to me but I'd try hooking it back on with a wire coat hanger with a slight bend in it. It's worth another few hours trying surely! MacGyver it back on! :lol

[Craiginuk]

Haha, yep just running out of steam. Plan was to clean carbs and sell it as i have not been using it. That turned into head off etc. will see but tempted to just sell as non runner or take to local garage to let them have a look.

[red98]

have one more go matey....you`ve come a long way,would be a shame to stop now when your so close to finishing..the reward of pressing the starter and it bursts into life is well worth all the hassle  ..600`s are selling well at the moment,easily fetch £1000....non running project maybe £300 ........