fzr400 exup

**Paul in NZ** · 4th June 2007, 20:55

Thanks Simon

I resisted the temptation to bodge this. If you look where the head nuts are - it's right under the cam saddles so not a good place to scratch with an L shaped allen key.

Vicki was headed to Porrirua to buy a zip to repair the leaf blower bag (what a bloody woman mate) and I found that Repco Porrirua had a set of metric hex attachments to suit the 3/8 drive socket set.

Fitted perfectly and got the head off with no damage! Cost $45 for the set but they fit the Guzzi etc and you have them forever.

Cheers

**xwhatsit** · 5th June 2007, 02:00

Valve grinding paste is cheap, might as well give it a go and see if it improves results with the kero test.

How well do you reckon the piston is sealing? Rings can't be too expensive for that, if you do them and hone the bore it'd probably go like a scalded cat. The piston/bore service limits must be written in the service manual somewhere.

I was informed when doing my single to just worry about cleaning the piston crown, unless you're pulling off the barrel anyway. Emery/emory paper/cloth/omgwtfbbq did the job well. It's a mucky bastard; is it just from running rich or has it been burning oil too?

Except you probably already know this, owning a Triumph and all.

**Paul in NZ** · 5th June 2007, 08:21

Originally Posted by xerxesdaphat

Valve grinding paste is cheap, might as well give it a go and see if it improves results with the kero test.

Thats a good point but the exhaust ports are well clagged up too... I'll see if I can find an engine reconditioner that will let me chuck it into their caustic bath to clean it all out.

Originally Posted by xerxesdaphat

How well do you reckon the piston is sealing? Rings can't be too expensive for that, if you do them and hone the bore it'd probably go like a scalded cat. The piston/bore service limits must be written in the service manual somewhere.

I was informed when doing my single to just worry about cleaning the piston crown, unless you're pulling off the barrel anyway. Emery/emory paper/cloth/omgwtfbbq did the job well. It's a mucky bastard; is it just from running rich or has it been burning oil too?.

Yup! Thats what I'm concerned about. Its running rough 'cos the valves are not sealing but poor piston ring sealing could contribute. If the rings are not poisenously dear I think I'll pull the block and renew them. The pistons seem really tight in the bore with no slop but there is quite a carbon lip up top.

Originally Posted by xerxesdaphat

Except you probably already know this, owning a Triumph and all.

Cheeky git!

Actually - it's much of a muchness, engines is engines but there are a lot less spanners needed on the yamahahaha and in predictable sizes as well! Quite liking it.

Cheers

**ZeroIndex** · 5th June 2007, 08:30

Originally Posted by Paul in NZ

Cheeky git!

Actually - it's much of a muchness, engines is engines but there are a lot less spanners needed on the yamahahaha and in predictable sizes as well! Quite liking it.

Cheers

Although on Yamaha's FZR's there is quite a bit of spanner-work needed for some simple maintenance... like removing the ENTIRE exhaust system for an oil change

**Fatjim** · 5th June 2007, 08:34

Mate, i can't help but think if you'd done just before and after pictures the thing would be done by now.

I'm starting get jealous, and the missus, if she new, would be starting to get nervous.

**Paul in NZ** · 5th June 2007, 08:36

Originally Posted by ZeroIndex

Although on Yamaha's FZR's there is quite a bit of spanner-work needed for some simple maintenance... like removing the ENTIRE exhaust system for an oil change

Is that just the EXUP ones - the other non EXUP system (rusty in the collector) seems to go to one side but yes - seems a bit of a fag for a filter change!

**Paul in NZ** · 5th June 2007, 08:39

Originally Posted by Fatjim

Mate, i can't help but think if you'd done just before and after pictures the thing would be done by now.

I'm starting get jealous, and the missus, if she new, would be starting to get nervous.

Well - the taking it to bits part is easy - it's the re-assembly thats tricky! The pictures help with all the connections etc and it's a way of making notes. Maybe my memory aint so flash anymore but I usually fill a notebook as I go along - speeds up the reassembly!

Don't be jealous or nervous - Trademe is full of projects...

**ZeroIndex** · 5th June 2007, 08:40

Originally Posted by Paul in NZ

Is that just the EXUP ones - the other non EXUP system (rusty in the collector) seems to go to one side but yes - seems a bit of a fag for a filter change!

'87 FZR400 SP model... same as my mate's '89 FZR250 (Exup too)

**skelstar** · 5th June 2007, 10:41

Am having a good time watching this Paul....keep going man!

**Paul in NZ** · 5th June 2007, 13:50

OK - just back from the yamaHAMER the customer shop.... Blurdy friendy lot - even offered me a stool to sit on before they priced up my request....

GACK!

I could dump $2K of 'bits' into this thing easy peasey without even touching the bottom end! Fark! Anyone know a cheap online source?

Paul N

(Stripping the second engine this week for useful parts and will NEVER moan about the cost of Moto Guzzi or old Triumph parts every again!!!)

**Paul in NZ** · 5th June 2007, 17:54

Given the shocking price of spares (ie more than the bike is worth here) I've been thinking that I'll have to be a bit cunning.... So I have devised a cunning plan..

The engine failed a dealer leak down test and my home one. Valves are all I can test so the rings 'might' be shot as well BUT when the bike was running it was using oil but not smoking...

What I could do is clean and build up the best head I can. Clean up the seats, lap in the valves etc and if that passes the kero down the inlet / ex port test, re assemble the engine using a new head gasket.

Since I don't have any shims I'll take the whole lot to the dealer (engines on the bench) and get him to set the valve clearances and repeat the leak down test. If it fails - it's probably got shot rings but it's only an hours work to lift the head / block and check em out...

Wadda you think chaps? Madness or cunning?

**MSTRS:Me** · 5th June 2007, 17:59

No Paul. It's being sensible. Only do what you have to. Otherwise, where does it end?

**Paul in NZ** · 5th June 2007, 18:56

Originally Posted by MSTRS

No Paul. It's being sensible. Only do what you have to. Otherwise, where does it end?

Bankruptcy according to yamahammer

**riffer** · 5th June 2007, 19:05

Originally Posted by Paul in NZ

Wadda you think chaps? Madness or cunning?

Put a tail on it and call it a weasel mate.

Although - what happened to that offer of another motor?

I can't help thinking that from two motors one good one may come forth...

**Paul in NZ** · 5th June 2007, 19:12

Originally Posted by riffer

Put a tail on it and call it a weasel mate.

Although - what happened to that offer of another motor?

I can't help thinking that from two motors one good one may come forth...

Yes - I have that (Thanks again mate) and thats what will happen to make 1 good head - then we move from there... Quite exciting really!