nath

Glad your sticking with it mate im rebuilding my FZ600 - have been since november! its been a pig to work on but got the engine rebuilt along with the forks, a new frame and electrics! just the brakes and the spark issues to sort then im not far behind you! im thinking either black and white, or yellow and white for mine though... Keep it up mate - it'll look mint when sprayed up!

ill stick the kettle on and get the bacon on then mate!

bit far from worcestershire matey - wouldnt you say? i think its the floats with the carbs tbh, by the time this is finished there wont be a single component which hasnt been tinkered with...

for reference it turned out to be a duff wire to the starter relay... turns over no probs now... Next problem is there is no bloody spark... typical... so im gonna swap the coils out unless anyone has a better idea... i get the impression that the leads cant be swapped on this type of coil pack???

Hi all, keeping this thread alive i thought i would post another few problems requiring attention... The engine is rebuilt... and fitted to the frame - the timing looks ok but time will tell however i took a brave pill and crudely cranked the engine over on the starter motor - attached to a car battery 'trick'... it spun over lovely and didn't implode or crap gears through the housing so im happy!!! Now my new problems have arose as ive reconnected the existing wiring loom, ive found that although i can get power to all lights and the neutral switch is functioning, the engine will not start - i cannot get the starter motor to turn over on the button... This is an intermittant problem which has become permanent over the last 2 days. initially the relay would click and buzz but would not turn the engine over. Then i disconnected the 'shorted' sidestand switch wiring and the engine turned over fine... so i connected the tank up to the carbs and pressed start once more... Nothing... And this has continued since then... A point to note is that sometimes on pressing the start button the oil light came on... however this no longer happens... So im well and truly stumped! Also upon connecting up the carbs to the fuel lines - fuel poured out the back of carbs 1 and 3 and out the overflow pipes... is a rebuild worth attempting or is it a specialist 'fiddly' job??? or better still can i just clean them with carb cleaner???

HAHA reading back on my thread ive missed a major section of the story out. so for those who give a sh*t! the engine cases were assembled and after assembly i noticed an odd looking piece just sat around next to the case (piece of the starter clutch) so it all was disassembled again - pieces replaced and all back together... then the starter clutch wouldnt 'ratchet' and was locked solid when the crank was turned - so it was split again and i noticed that in my haste a load of crap has found their way onto the big end shells and when the crank was turned it scored them... so back to yamaha for 6 new shells and to find that they no longer stock the shim which sits in the started clutch (which was cutting into the starter clutch itself... nor do they stock the guide for the hyvo chain any more... so lots of loctite on the remaining pieces of chain guide and its locked into position nicely - minus the centre piece. the shim was filed down with a metal file and placed back into the starter clutch (with no ill effects as yet). New bearings to replace the scored set and the whole lot was cleaned with paraffin and then blasted with an airline. I was going to replace the pistons, rings and cylinder with that of the spare engine however the bike had been dropped at some point knackering all the fins on the cylinder - so the originals have remained... to my detriment possibly! i have nicked the clutch from the spare engine as the plates had more meat on them - oh and dont EVER buy the aftermarket gasket kits that retail for about £80 - a tube of instant gasket by loctite is sufficient with a head gasket from yamaha. The aftermarket gaskets are poorly made and dont have half of the pieces you require for a full rebuild... if anyone wants advice into how to build an engine the hard way just PM me lol

Hi all - i dont know - i go off to do my exams and suddenly everyone starts to rebuild FZ600s and i miss out on all the Goss!!! Right heres where im at (i dropped my laptop - buggering the internal bluetooth somehow - so pics are a no show at the minute) 1. The engine is assembled apart from the cams (im shitting myself about the timing setup as haynes isnt helpful) 2. Frame is cleaned up and resprayed white - i bought a new frame from ebay so the bike will now be an 'F' reg instead of an 'E' reg. 3. The loom still requires attention as the previous owner butchered it more than i thought... 4. the bike is 85% done - the LH fairing requires spraying in yellow/black as the old one fell off on the M18 (they shatter at speed) Overall im happy with how its going... its difficult to know if the engine will run (fingers crossed) it'll need the carbs retuning, a new chain and new brake pads... oh and retaxing Finally quick technical question - are there any tips with the timing arrangements, i have the no.1 piston at TDC but am aprehensive as to how to approach the next step... p.s. jimR rules...

Jim is a legend - hes the only reason im still grappling with rebuilding my FZ600; which is nearly finished after 6 months of scraped knuckles and melted credit cards! Cheers matey!!!

Legendary! and yet creative at the same time...

that back end... defo my next mod!!!

Ok heres a good one - crankshaft oil seal, ive bought a new one from yamaha and it lacks a 'lip' going around it so therefore it wouldnt be retained in position as the engines running... fair play i think so i take it back with the original showing the difference... not so says the nice parts man, the 'new' type of oil seal is without said lip to allow for replacement without splitting the case halves... Have i just swallowed someones bullsh*t here? i mean its fitted now of course, ive even put silicone around it to make sure but if i rebuild this whole engine for the seal to move when i fill it with oil i wont be happy with the nice parts man... what say you??? oh p.s. Starter clutch fitted Crankshaft fitted Transmission fitted tomorrow: case halves together (when i find that pesky dowel) oil pan + gubbins Clutch then who knows??? beer methinks!!!

yeah ive had that feeling for a while jim... i'm canibalising an old 2HW for the guide and putting the old chain back in as yamaha have discontinued the parts... just purchased the oil seals to go on the crank... its an arse to be sure but hey sh*t happens and learning curves usually are steep! not long now though i hope... the unit might be finished by monday! Quick Edit: famous last words... managed to shear or round about 5 bolts before being rained off... i remember how much of an arse it was last time to strip an engine... i guess it can run without the full guide... half will have to do!

Right then peeps the cases are cleaned to within an inch of their lives, the crank is rebuilt with new big end shells and tightened to 25Nm with my new torque wrench... Question is this... upon inspection i saw that the starter/drive chain guide has snapped into three pieces, with a small section loose in the case miraculously held in place by the two larger sections still bolted to the upper case. Ive ordered a new one from Yamaha (£15) which will hold me up for a few days, is it possible that this is the source of the rattling noise??? also the the chain looks intact with little signs of wear, however according to haynes the chain links should not 'touch' when sat on the bench, whereas this chain does sag in the centre... Ive priced up a new chain (£137+vat), so i laughed heartily and am asking whether its practical to reuse the old one and whether there is a risk of breakage... Quick Edit: can the engine run without the chain guides??? are they crucial to safe engine operation or will it leave slack in the chain???

haha no its alright - quite interesting having people who remember when they were new... i was 3 years old when mine was registered!!! people think im mental being 23 yet liking things from the 80s... Frame got cleaned down today and im gonna spray it to get it nice - white i think (any objections) also interesting fact - ive removed the rocker cover from the 2HW engine today and the timing is different from the 3KM... with the 2HW firing something like 1,3,4,2 and the 3km definitely firing 1and4 then 3and2 together... strange sequence i thought... anyway the head will be off the 2HW soon so i can nab the pistons, rings and cylinder then its off to a mates garage for some airline and paraffin cleaning and reassenbly action...