Goto page 1, 2, 3 ... 15, 16, 17  Next
 
Post new topic   Reply to topic    Exup1000.co.uk Forum Index -> Rogues Gallery
View previous topic :: View next topic  
Author Message
banner001
Pit-lane Reporter
Pit-lane Reporter
Joined: 25 Sep 2012
Posts: 740
Location: Nuneaton, UK
PostPosted: Wed Dec 12, 2012 12:59 am    Post subject: Vivian - Banner's streetfighter experiment. Reply with quote

I always name my bikes starting with the letter V, this is Vivian, i also currently have Victor (my uk-spec 1994 zxr 400), this is combined from another forum... dont think i have done all the following in 1 day big grin

i have a new project...1989 Yamaha FZR 1000 EXUP, 46k miles, V5, £400 and 4 cans of beer delivered to my place big grin The fairings, tank, carbs etc are all scattered about the place in the loft so its a complete bike, but its getting fully stripped anyways big grin



its strange looking down an intake port and seeing 3 valves...
Back to top
View user's profile Send private message
banner001
Pit-lane Reporter
Pit-lane Reporter
Joined: 25 Sep 2012
Posts: 740
Location: Nuneaton, UK
PostPosted: Wed Dec 12, 2012 1:01 am    Post subject: Reply with quote

first thing will be to get a spark, it cranks fine, but no spark...i suspect its just a wiring fault/dodgy kill switch etc...once thats done it will get the loom hacked into big grin looking at a LiPO4 battery and custom case to centralise the mass, relocate all tail electrical relays etc to this new battery/electrics box. a friend suggested fitting a more modern pump and getting rid of the fuel pump relay - will look into this. Either gonna fit small bulb indicators, or wire in proper LED relays (as opposed to resistors).

am going to wuss out of designing a brand new look and basically copy this ()...with a large matt black stripe running down the centerline of the bike and over the tail, with a matte red pinstripe either side, frame will be powdercoated black, downpipes will either be painted black, or wrapped in heatwrap, or both. mainly to keep them from getting damaged/corroded as they are in OK condition...but not fantastic, and new replacements with the EXUP housing i cant seem to find...only race systems without it...the general consensus seems to be to still stick with the exup valve...we will see.

want to get the weight down, its about 236kg fully oiled and fuelled (apparently) and probably about 125bhp (46k miles on the clock, supposed to be 131bhp...), would like to get this towards the 200kg mark and ~140bhp mark. my zxr for comparison is ~180kg and 55bhp.

so thats 0.305bhp/kg for zxr, 0.529bhp/kg (stock fzr), 0.7bhp/kg (lightened fzr)

with me on board in gear +90kg:-
0.203bhp/kg for zxr, 0.383bhp/kg (stock fzr), 0.482bhp/kg (lightened fzr)

...so its got almost twice to power/weight ratio that my current bike has...should be good fun tearing the thing apart big grin
Back to top
View user's profile Send private message
banner001
Pit-lane Reporter
Pit-lane Reporter
Joined: 25 Sep 2012
Posts: 740
Location: Nuneaton, UK
PostPosted: Wed Dec 12, 2012 1:01 am    Post subject: Reply with quote

bike is getting delivered next wednesday

in other news, a friend of a friend has a powdercoating business so i will be taking it there to get done, looking at £100 for the wheels and £150 for the frame and swingarm.

new i have access to somethings that he can use, so im gonna get a £250 powdercoating job for £0

will be matte black powdercoating, with a surface laquer on everthing except the wheels. when i get the plastics and tank sprayed i will get the wheels pinstriped in the same orange paint so they all match, then get them laquered to protect them.

i just want it to arrive now
Back to top
View user's profile Send private message
banner001
Pit-lane Reporter
Pit-lane Reporter
Joined: 25 Sep 2012
Posts: 740
Location: Nuneaton, UK
PostPosted: Wed Dec 12, 2012 1:02 am    Post subject: Reply with quote

update:-
-sorted out a "to sell pile" comes in at over 15kg of mass so far...
-rear wheel removed along with most of my years aggression, spindle was almost welded in with rust...took several days to remove it with a rubber mallet.
-bike was originally only cranking, cleaned up plugs, reattached HT leads, connected a new batter, carbs on, bit of fresh fuel, connect all electrical leads, bit of engine oil...and it fired up for first time in 4 years.
-have removed front headlights, city light, front indicators and clocks, have removed all electrical connections from the front of the bike, i will be re-making all the connector blocks up fresh with all-new connectors then packing it with di-electric grease and sealing with tape, should keep it waterproof (not that its going anywhere near rain).
-powdercoating is going to come in at 220, a 3-colour paint job is looking like ~400 which is good to know.
-engine has a flattened and seived allen bolt, LHS underneath the cam cover...bolt is hardened steel so my stud extractor did nothing, am gonna try JB weld and a bolt to try to free it...if not i can wedge the frame slightly and cut it, not ideal, but other guys have done it and managed to mole-grip the bolt out afterwards...or i can get an actual nut welded to it and break it that way...
-am in process of removing the last of the electrical connectors (relays, exup valve, CDI etc...) then i can start to chop into it, gonna remove the sidestand and clutch switches first, then i will look at wiring in LED relays for the indicators, need to source some new headlights (probably chrome ones) and wire them up properly. once thats done i have 2 sets of "spare" connectors to remove, several lengths of wire to cut down already, followed by adjusting the CDI, fuse box, relays etc...so that they sit on the (still to be designed and constructed) subframe for the (still to be assessed and purchased) single seat tail unit.
-need to decide what to do about a seat, will depend on what happens with the tail unit, i like the idea of the old 500cc 2-stroke GP bikes which were just a foam pad ontop of the plastics...but i guess that more reinforcing will be needed for the road. cant make my decision until i decide upon a tail unit.
need to look at securing the radiator and oil cooler to the engine block in a better way than current (all horrible angled and rusted steel), will also need a meter stay/clock mount when i decide on the correct headlights and digital display.

pics to follow.
Back to top
View user's profile Send private message
banner001
Pit-lane Reporter
Pit-lane Reporter
Joined: 25 Sep 2012
Posts: 740
Location: Nuneaton, UK
PostPosted: Wed Dec 12, 2012 1:03 am    Post subject: Reply with quote

"quote"matt black will show every scratch/mark i went for satin black on mine [url=http://www.zxrworld.co.uk/zxr400oc/viewtopic.php?f=87&t=2634&hilit=finished+with+my+woman]see here.

the frame will need a good bit of prep before it goes to the powdercoaters, gonna make sure its pristing before it goes...not like im in a rush for it, so i can do a proper job.

there are a few frame mounting points to remove (where the fairings joined), one of the engine mounting allen bolts has been ground flush and has seized slightly so that area will need sanding smooth...all the current frame scratches will be 240/400 grit sanded back, once the engine is out the frame will be a lot lighter so i can then remove the swingarm and start to work on that as well big grin

mounting bolt


current state of bike (am removing the electrics for a full re-wire)


thankfully its not a complicated loom


i have made sure to label everything and take photos of it all!
Back to top
View user's profile Send private message
banner001
Pit-lane Reporter
Pit-lane Reporter
Joined: 25 Sep 2012
Posts: 740
Location: Nuneaton, UK
PostPosted: Wed Dec 12, 2012 1:04 am    Post subject: Reply with quote

that engine bolt...damn!

drilled and easy-out...nothing.
pack it with JB weld and ram a screw in there...nothing
JB weld outside and stick a nut on...nothing

in the end a forum member said its fairly common, hacksaw through the bolt just behind the frame and weld a nut on after and do it that way, if not it will be properly drilled and tapped later.

bike has shed more weight


back end is looking pretty bare now, now to decide on tail ends...will be a modern 600 or 1000cc bikes tail end going on, something small sleek and pointy methinks



gonna drop the engine today with the help of my wife and a mate of ours...thinking its gonna be ~110kg?

then i can start the full engine stripdown on one bench, and start attacking the electronics on the other big grin
Back to top
View user's profile Send private message
banner001
Pit-lane Reporter
Pit-lane Reporter
Joined: 25 Sep 2012
Posts: 740
Location: Nuneaton, UK
PostPosted: Wed Dec 12, 2012 1:04 am    Post subject: Reply with quote

engine is out! needed to be tipped forwards a fair bit before it eased its way out (was a bit gummed-in at the back), is now on my bench ready to be stripped down


big grin
Back to top
View user's profile Send private message
banner001
Pit-lane Reporter
Pit-lane Reporter
Joined: 25 Sep 2012
Posts: 740
Location: Nuneaton, UK
PostPosted: Wed Dec 12, 2012 1:05 am    Post subject: Reply with quote

engine stripdown is commencing big grin

my socket has just snapped (literally) so thats gone in the bin, am awaiting a breaker bar delivery, been taking external bits off the engine


sorry for shaky picture...but it was damn cold last night at 1am big grin top of the engine, will take the cylinder head off when my breaker bar and 6mm long reach allen socket gets here...


the timing cover was held in by 3 head-stripped screws...manages to get 2 out, the 3rd has snapped...so that will require extracting at some point, have been removing the alternator and reg/reg (one unit), the starter motor, oil pressure switch and the neutral sensor...


more in a few days, might spend tomorrow cleaning up the usable piping for the cooling system, its bad on the outside, worse on the inside big grin
Back to top
View user's profile Send private message
banner001
Pit-lane Reporter
Pit-lane Reporter
Joined: 25 Sep 2012
Posts: 740
Location: Nuneaton, UK
PostPosted: Wed Dec 12, 2012 1:05 am    Post subject: Reply with quote

still working on the engine, have put the tank on the frame to check a few distances/sizes etc...

am gonna make a custom mount for the front...current one is all open and well ugly, will make a fiberglass cover and reposition the mounts wider.


might try to drop the tan a few mm to close this gap, if not i will fit rubber mounts so its tight to the frame.
Back to top
View user's profile Send private message
banner001
Pit-lane Reporter
Pit-lane Reporter
Joined: 25 Sep 2012
Posts: 740
Location: Nuneaton, UK
PostPosted: Wed Dec 12, 2012 1:06 am    Post subject: Reply with quote

clutch will need new plates and springs...clutch friction plate minimum thickness = 2.8mm, mine = 2.1mm

spring minimum free length = 54mm, mine = 48mm...will stick new steels on as well, clutch hub seems fine.
Back to top
View user's profile Send private message
banner001
Pit-lane Reporter
Pit-lane Reporter
Joined: 25 Sep 2012
Posts: 740
Location: Nuneaton, UK
PostPosted: Wed Dec 12, 2012 1:06 am    Post subject: Reply with quote

vivian has taken his suspenders off...


am 98% of the way through the main stripdown, just gotta remove the headstock and swingarm pivot bolt...then its all done...just hope i can put the damn thing together again now haha!


have pulled off most of the dirt, shouldnt take too long to get it all cleaned up
Back to top
View user's profile Send private message
banner001
Pit-lane Reporter
Pit-lane Reporter
Joined: 25 Sep 2012
Posts: 740
Location: Nuneaton, UK
PostPosted: Wed Dec 12, 2012 1:07 am    Post subject: Reply with quote

cylinder head, no idea when/if it was ever last taken apart, might have done +46,000 miles and its in pretty good condition considering some ive seen...


cant remember what its called, but these are the pistons in the barrels.


probably the worst bit of the head


and the best


worst piston crown


best crown


5 minutes cleaning to the "worst piston crown" gave me...

...which is encouraging

am borrowing a valve spring compressor on wednesday or friday, will get my mate to bring his impact gun and we can take out 3 slightly-mashed, very seized, pozidrive screws so i can split the crankcases over the next week or so...
Back to top
View user's profile Send private message
banner001
Pit-lane Reporter
Pit-lane Reporter
Joined: 25 Sep 2012
Posts: 740
Location: Nuneaton, UK
PostPosted: Wed Dec 12, 2012 1:08 am    Post subject: Reply with quote

Pistons are removed from the top of the conrods, and i only lost 1 of the metal split ring things! Will replace with new anyways. Everything looking good, no nasty lumps of metal anywhere, some small "ribbon" bits of metal, but it almost looks like bits of the very edge of a gasket, its very small and very thin so no big deal. nothing looks damaged/scored/moves too much etc...so thats looking up.

the only problem so far has been that the exhaust camshaft feels very tight in its housing on the LHS of the engine, part of it slots into a groove (i think its an oil passageway or some kind) and i think thats the bit thats tight, inlet is nice and spun freely, but the exhaust camshaft did feel very tight when i had to remove it, might have to look into that further...might be fitting new cams anyways...we will see, stock will go back on initially.

been hammering the sh1t out of the swingarm, manual shows a guy easily sliding it out of its housing...not mine, the easiest bit was the 130Nm nut! This is what greeted me on half of the swingarm


Completely rusted in place, no wonder it took 30 minutes of braying it with a rubber mallet...the inner cylinder was not much better either, no grease in sight, what was in sight was more rust, yay!


arent needle rollers supposed to roll?...will get them out at a later date


gotta get this cover off of the end of the camshaft, remove the clutch, then i can crack the cases and remove all the rest of the inside, ready for cleaning, sand-blasting, more cleaning, measuring/tolerance checking and reassembly...fun fun fun big grin
Back to top
View user's profile Send private message
banner001
Pit-lane Reporter
Pit-lane Reporter
Joined: 25 Sep 2012
Posts: 740
Location: Nuneaton, UK
PostPosted: Wed Dec 12, 2012 1:09 am    Post subject: Reply with quote

been cleaning the frame and the swingarm. a quick taster of the swingarm, still needs at least 1 more clean, but damn its a lot better than before!!


im gonna go for this tail unit, unsure as to whether to go for a tank pad (as in picture), or get a seat made for me, the latter would be comfier, but the former is the easier option...
Back to top
View user's profile Send private message
banner001
Pit-lane Reporter
Pit-lane Reporter
Joined: 25 Sep 2012
Posts: 740
Location: Nuneaton, UK
PostPosted: Wed Dec 12, 2012 1:10 am    Post subject: Reply with quote

need to get the tail unit and rear brake ordered...the old one was completely corroded...had to hacksaw it off! will probably get an R1 rear, as i am looking at an R6/R1 radial front at some point...

get the tail unit, then i can build the rear subframe and tail tidy. i will also make a one-off rear brake caliper holder, might try to copy the R1 where its a bar welded to the inside of the swingarm, or whether i will just get a small torsion arm made and mount it under the swingarm...im still undecided on a small rear hugger or not.

then its sorting out the rear shock (might go with a racing-type on with the compression on a thing that sits above the shock...you know what i mean), but if so i will need to mount the battery somewhere different...wanted to put it above the shock to mass-centralize a bit...will have to see if i can learn something like autocad and have a play about?

then i can get the rear electrics and all the relays/EXUP servo/CDI etc. relocated under the seat, again, want to get these just about under my butt, to get them forward.

its getting to the stage where i need to spend money now 114 (tail), 100 (frame powdercoat), 50 (misc welding), 100 (tooling), 150 (custom aly subframe)...dont tell the wife
Back to top
View user's profile Send private message
Display posts from previous:   
Post new topic   Reply to topic    Exup1000.co.uk Forum Index -> Rogues Gallery All times are GMT
Goto page 1, 2, 3 ... 15, 16, 17  Next
Page 1 of 17

 
Jump to:  
You cannot post new topics in this forum
You cannot reply to topics in this forum
You cannot edit your posts in this forum
You cannot delete your posts in this forum
You cannot vote in polls in this forum


www.exup1000.co.uk is owned and run by EXUP enthusiasts, for EXUP enthusiasts
Powered by phpBB © 2001, 2002 phpBB Group