Yamaha FZX 750 Rebuild

2011-09-29T15:50:00.001-07:00

Fuel bowl plates

2010-11-09T11:27:00.000-08:00

An update on the finished fuel bowl plates.
These are fixed under the fuel bowls, keeping everything in place and preventing bowl distortion and leaking.
There are some new CNC machined billet fuel bowls, and machined plates, but I like to do things myself. (And often fuck up everything in the process).
You can check out some fuel feeds I made on the lathe also.
The FZX frame is a bitch, with those two upper frame rails right in the way of the carbs, so you have to get around things sometimes to make everything work right (without resorting to heavy power tools or big hammers...)
Enjoy.
Comments always welcome...

Motörhead - We Are Motörhead

2010-10-08T08:07:00.000-07:00

Just for kicks...
Live at Brixton Academy,London (25th Anniversary)

30mm Shells

2010-09-17T14:20:00.000-07:00

Just for fun, I had these 30mm shells from the Fiat G91 aircraft laying around and thought about turning them in the lathe and polished them.
Not sure yet what I'm going to do with them. Bar end weights, footrests...?

Lectrons Update

2010-09-17T13:33:00.000-07:00

Just some pics of the mirror polished bell mouths.
Do these look sexy or what?

Lectron carbs

2010-08-17T13:18:00.000-07:00

Rebuild is going real slow.
For a good build you need at the very least least two things: Time and money.
I have time (unemployed), money I don't!
So, everything I can do myself is being done; engine rebuild is in stand by for now, Wiseco 1029cc kit and all parts (gaskets, bearings, orings...) will have to wait.
Meanwhile I turned my attention to the 40mm Lectrons I'm going to fit.
I bought these carbs years ago from Manny (from Canada), tried them for a short while, but these things are not very streetable. They are more suitable for a Garage Queen, which is what my FZX is becoming after all these years.
I disassembled the rack, disassembled each carb completely, blueprinted and removed and deburred all sharp edges, polished the slides and bell mouths. Converted them to metric screws (sorry).
Machined a new twist wheel on the lathe and made new top covers for all 4 carbs.
I'm thinking about converting the carbs to powerjets. Powerjets are used mainly on two-strokes, but it's a good idea for four strokes also, because you can have a richer top end (with the powerjet) while using a leaner needle for better bottom end and mid range.
Lectron carbs don't use jets (except the powerjet). Only a specially cut needle that does it all. Simplicity at its best.
Something I like to say:
The beauty of engineering is in the simplicity.
For those of you not familiarized with these carbs (made in USA) check http://www.lectronfuelsystems.com/

A small video of the Lectrons.
We call these Guillotine carbs. Guess why...

Home made milling machine. The plastic fuel bowls are prone to distort and leak, so I'm making these plates to keep everything tight and sealed.

General view.

Notice twist shaft and twist wheel.
Lectrons usually have direct individual throttle cables.

New twist wheel turned on the lathe.

Converted to metric.

New top covers cut and polished.

Polished slides

Headlights

2010-07-05T14:15:00.000-07:00

Ok, every time I go to the bathroom or open a nice cold one (some times both at the same time) I change my mind about something on this rebuild.
I found my "CyberMax" headlight, made originally for the Vmax, in my old "box of bits and parts".
I bought this headlight years ago from Exactrep (www.exactrep.com) for my Vmax, used it for some time, then changed it for something else and stashed this away.
Check out the pics and feel free to comment on your preference.
I like the classic retro square headlight, but this "Alien" thing just looks too cool...

June 2010 Update

2010-06-20T12:30:00.000-07:00

Ok, rebuild is going slow, but here are some updated pics.
I've changed the rear brake caliper hanger position, you know how it goes, as builds progress, some things change along the way; some to solve a particular problem not initially predicted, others just because I changed my mind.
I'm using an underslung caliper hanger position, using a longer home-made torque arm, Vmax disc, caliper and hanger. This way I get a cleaner look on the rear wheel.

I wanted to fit a double headlight but keeping the square light trademark of the FZX.
I bought this headlight from M&P (www.mandp.com), which is exactly what I wanted.
I have the rolling chassis almost ready, just small bits and bobs to fit, build and solve.

I'm going to design and build some front engine mounts from 10mm thick aluminium. the stock front mounts use two 8mm bolts to the frame, but there's an extra 8mm bolt mount that's not used (???)
The idea is to build a triangle shaped mount, using three 8mm bolts to the frame and other to the engine.
Let's see how it will look...

Another detail, I decided to to stretch the wheel base to max, using extra lenghts of chain.
What are you gonna do, I can't help it, I like them long and low...

Frame

2010-04-13T11:34:00.000-07:00

Using the FZR1000 engine, I thought it would be a good idea to stiffen the frame at the swing arm pivot area.
I made some cardboard templates and cut the frame reinforcements from rectangular box section steel.
Black paint in the pics was just to get a general look of the (crap) job.
After welded, everything will be sanded, prepped and painted matte black.
I'm crap at welding, please bear with me. This was done with stick welding, using 2,5mm rods.
I'm saving some euros to buy a good quality MIG welder. Easier to weld and nicer looking welds.
Feel free to comment...

Front end part 3

2010-02-28T06:43:00.000-08:00

Ok, more on the front end saga...
The YZF750 forks are in, with new seals and fork oil.
The FZX stock wheel is in, with the special axle adapters I had made (check previous post, Front end part 2), since I'm also using the stock FZX axle.
I got some used Yamaha R6 brake rotors from Ebay (bolt-on onto the FZX wheel)
The YZF750 6pot calipers didn't align with the R6 rotors so I had to make a couple of caliper hangers from Naval quality 10mm thick aluminium.
I made some cardboard templates first, just to get the basic shape and measures.
The pics show just a rough cut of what the hangers will look like.
They will be fine shaped and mirror polished.
In addition, safety lock wire will be applied to all 4 caliper bolts.

Front end part 2

2010-02-16T15:27:00.000-08:00

The triple trees are on.

Fresh steering bearings. The stock adjusting nuts have a rubber washer between them. I usually replace this with a solid metal washer and tight the two nuts together as per factory specs.

The top triple tree is from RairoTec, I got this on Ebay real cheap a few years back. It's CNC machined and comes with bolt-on risers to use your stock handlebars or dragbars.

I'm using clip-ons, so the risers are on the shelf for now.

I wanted to do something for a while now, and decided this was the perfect time.

I wanted to be able to use the stock wheels for two purposes:

1- For that "old-school street special" look;

2- They're preparing to have bikes go through a MOT annual inspection (Yes I know, we're lucky bastards so far), so bikes will need factory spec wheels and tires to get approved (probably).

Older design bikes are of course much safer with modern wheels and suspension, but go tell them that.

They discard all responsibility of having to judge if a 17" wheel conversion job is safer or not, so it's easier to say "bikes must have all factory specs", end of story. Bastards...

I needed a quick way to change wheels without to much hassle.

So...

(Here I go again, letting out all my secrets...)

I had two adapters/spacers/sleeves made, that allow me to use the stock FZX wheel and axle (spindle) on the YZF750 upside down forks.

But for this you need BOTH fork legs to have clamping bolts for the wheel axle. This is a must.

Front end

2010-02-16T14:04:00.000-08:00

I'm using the complete front end from a '94 Yamaha YZF750 Exup.
I rebuilt the front forks with new seals and good quality 10W fork oil. The springs are Ohlins.
As anyone who've replaced seals on these suspensions knows, it's a b*tch to get the spring spacer and fork cap back on without someone assisting you.
I was really pissed about not being able to do this on my own (again), so I scratched my head, and about two beers later, I designed this in my head and built it using some steel threaded rod and scrap metal bits.
It's ugly as hell but it works, and that's all that matters to get the job done.
The bottom end attaches to one of the brake caliper mounting holes, and the top "grappling hooks" fit in the metal spacer (which has one hole on each side for this purpose).
With one hand holding the spacer/hooks (with a heavy leather glove on, just in case), and the other with a 13mm spanner turning the nuts (which have been welded on to the steel rod), thus pushing the rod and hook/spacer down.
When it reaches the fully compressed position, you can simply pull up the fork dampening rod and attach the fork cap back on. Presto.
Just as a sidenote for all the lads on the FZX Club:
Notice "The BIG Hammer", on the second pic. Always have the big hammer near by, for when things don't go as you liked to. That, and lots of beer...

Rad cover

2010-02-01T14:34:00.000-08:00

I got this great stainless steel, laser cut rad cover from Woz.
He's one of the lads from the FZX Club and he makes these awesome custom made radiator covers for the FZX, in "FZX700", "FZX750" or "FZX1000" layouts.
Check it out.
Thanks Woz, great product!

STUFF FOR SALE

2010-01-18T13:45:00.000-08:00

This post will be permanently updated with stuff I have for sale.
All parts are used, with the usual cosmetic damage, but in good usable condition, otherwise noted.
Please note, used means used. If you want new, buy new.
More pics upon request.
I'm based in Portugal, shipping charges will be added to the item price.
Thanks.

- Vance & Hines Ignition Advancer NEW, inside the package, to fit the following models:
GSXR600 92-93
RF600R 94-98
GSXR750W 93-95
RF900RR 94-96
GSXR1100W 93-98
50 Euros

- '92 FZX750 Swingarm w/ wheel axle
50 Euros

- '88 FZR1000 Genesis Swingarm w/ wheel axle (Damage on one of the bearing metal seals, probably due to the chain rubbing)
50 Euros

~~- '88 FZR1000 Genesis Radiator w/ fan (was taken of a running bike)~~
50 Euros (SOLD!)

~~- '95 FZR1000 Exup Rear brake assembly complete~~
30 Euros (SOLD!)

- '88 FZR1000 Genesis Rear brake assembly complete
30 Euros (Pics to be added)

~~- '88 FZR1000 Genesis Starter Motor (Mitsuba SM-13)~~
50 Euros (SOLD!)

The Special bit...

2010-01-16T10:39:00.000-08:00

This is, without a doubt, the most special bit I have on my bike.
I made this a while ago, dedicated to my late uncle, J. L.
I cut a good quality aluminum stripe, the flame design was drawn by hand, mirrored and inverted for the left/right sides to be symmetrical.
Then the dificult part begun. This little piece was all made by hand. And I mean "oldschool by hand".
It was entirely hand cut, hand filed, hand sanded and hand polished by myself.
No, it's not perfect like CNC machines do, but that's why it's called "hand made".
R.I.P, Jonny, thanks for being a part of my life.

Rear sets

2010-01-16T10:14:00.000-08:00

I removed all the stock footpegs, foot controls and brackets/plate/support.
I made two triangle shaped support plates from Naval quality aluminium.
Attached them to the frame as you can see.
I used complete stock rearsets assembly from a '94 Yamaha YZF750R.
One mounting point on the aluminium plate, the other on the frame.
I made an extra hole in the custom plates to alter the footpegs position further back if wanted.
I rebuilt the stock YZF750 Brembo rear brake master cylinder and gave it an slight buff for extra shine.
I made the brake fluid reservoir from one of those cheap aftermarket fuel filters. Think it looks good enough.

The seat

2010-01-08T15:04:00.000-08:00

Well, the seat was still in its original 1992 cover (upholstery).
Very worn out and slippery.
I had the foam carved and shaped to my personal taste ages ago, but the cover was still the original one.
I had the seat reupholstered by a friend whom I frequently assist and service on his custom bike projects.
This is not a state-of-the-art job, but I think it's good enough, mainly because it costed me next to nothing. :-)
Respect.

Front brakes

2009-12-31T18:23:00.000-08:00

I just got this entire lot from a '95 FZR1000 Exup for 50 Euros delivered to my door!
These 6 pots are hard to find and expensive even on Ebay.
They came with almost new pads; they're in need of a lick of paint but I think this was a bargain...

Torque arm

2009-12-31T17:49:00.000-08:00

Home made torque arm...
I had a couple of rose joints laying around (from some old steering dampers), so I thought about making a new torque arm, using steel thread rod, steel tube over it and a couple of nylock nuts to get the rose joints aligned in the right direction.
I always liked the look of these things; slim and clean...

Rear end part 2

2009-12-31T16:27:00.000-08:00

Ok, some updates and details on the rear end.

Left and right side axle spacers...

First thing to do was to choose the correct left spacer to get the wheel perfectly centered...

I had to make a couple of small spacers to offset the brake caliper to the left so it wouldn't touch the disc and get everything right and centered...

Other options were offseting the brake disc to the right, with M8 washers;

or cuting the axle spacers to get the caliper hanger in the right position...

But I'm working with what I've got in the spare parts and bolts & nuts bin, as this is a project on a budget (very small budget for that matter), and machining and milling time costs $$$, so almost everything is done in-house.

Rear end

2009-12-21T14:37:00.000-08:00

For the rear end, I'm going to use my ever faithful JMC extra long swingarm, although this time the chain adjusters will be at their shortest wheelbase position.
I'm going to use a single stock Yamaha FZX chain drive kit.
I'll use the Vmax shocks for the "Cafe racer" look...
or the Progessive Suspension 11" shocks for a lowered dragster stance.
Along with that, I'll fit (again) the Kawasaki ZZR1100 (ZX1100 in the US) 17" x 5.5" rear wheel.
For the rear brake system there's a:
- Vmax/R6/R1/YZF600/YZF1000 front brake rotor fitted in the Kawasaki wheel (bolt-on);
- '96 Vmax front right caliper (or any regular 100mm yamaha front caliper, including the gorgeous blue spots from the R1/R6)
- Vmax custom caliper hanger for use with the 4 pots and front brake rotor. (there's loads of these for sale on Ebay or Vmaxchat)
- Home made rosejoint torque arm.
The CNC caliper hanger was fited with a bushing to reduce from 20mm to the 17mm of the FZX rear axle.
Next you just have to center the wheel in the swingarm and fit some aluminium spacers to get everything tight.

The engine...

2009-12-18T16:20:00.000-08:00

Well, not sure what to do about this yet...
I took the engine off the frame and did a compression test.
Standard for the '88 FZR1000 Genesis is 11kg/cm2.
I have low compression on #4 cylinder:
#1 - 10.5 kg
#2 - 11 kg
#3 - 11 kg
#4 - 9.5 kg
I had the valves adjusted a while ago, so I think this may be a piston/cylinder/rings issue.
I haven't opened up the engine yet, because I haven't decided yet what to do:
Rebuild this engine with a 1029cc Wiseco big bore and fit the 40mm Lectron carbs
or
Get a FZR1000 Exup or YZF1000 ThunderAce engine and turbo it.
I know ThunderAces have stock forged pistons and this would be good for turbo use.
I'm planning a fairly low boost, medium compression, and about 200/220hp target, running on pump gas.
In portugal we have 95, 98 or 100 octane unleaded fuel, so I think this is not a problem.
I'd like to build an "old school street special", and the turbo route is a good challenge.
I've never turbo'ed an engine, but I'm pretty aware of the work/trouble/sweat/tears/swear involved.
I've been researching and reading a lot about turboing motorcycles and I'm pretty sure I'd be the only twat with a turbo bike around here... :-)
Anyway, this will be a long term project, I'm sure I'll have the rolling chassis ready long before the engine.

Lowering the bike

2009-12-18T15:57:00.000-08:00

When using the 11" shocks to lower the bike, the swingarm almost touches the battery support.
To prevent any swingarm/frame close encounters, I cut off the battery support as you can see.
The plastic box where the battery fits, rests in this support and is attached to the frame on the left and right side, so I think there's no problem by cutting off this little piece.

Coolant in the frame

2009-12-18T15:13:00.000-08:00

I never really liked the idea about the coolant running inside the left lower frame rail, from the radiator to the water pump.

So the "in" and "out" were plugged.

I bought two cheap rubber plugs from an auto parts store.

I'm going to run a long braided coolant line from the radiator to the water pump.

I'll have to use the FZR1000 water pump cover because the inlet faces forward, to catch the line coming from the radiator.

Coils

2009-12-18T14:29:00.000-08:00

The FZX coils are located under the left and right chromed "7" shaped pieces on the tank/airbox cover.

As I run individual air filters, I thought about moving them to the inside of the top frame rails, so they wouldn't be so exposed to moisture and rain.

I must confess, i saw this done originally on SatinBlack's FZX, so, as it was a great idea, I had to do it myself too...

Sorry about the horrible welding, the electric grid on my garage does not support the arc welder more than 2 seconds before switching off.

Must sort that out...

Down to the frame

2009-12-17T16:12:00.001-08:00

Well, as you can see, it's down to the frame.
All cleaned, new lick of paint.
Swingarm bearings were ok, cleaned and freshly greased.
The coil brackets were cut off and welded on the inside of the top frame rails.
NOTE: You can only do this if you use individual air filters.
The frame coolant inlet and outlet were plugged as I never really liked the idea of the coolant running inside the frame. I'm going to use a long braided coolant line from the radiator to the water pump. I'm going to use the FZR1000 water pump cover because the inlet faces forward where I need it.