FZR400 project

**manwithav8** · 28th September 2007, 20:16

Well I asked here a little while ago if I should take up the offer of a FZR400 for $150. After speaking to the law and finding out there is no vested interest in the bike I snapped it up.

The information I was given was that it is complete, all parts there but it hasn't been going for two years. First initial thought was "damn, is it worth the hassel" but then I also though for $150 I could at least part it off an at minimum get my money back.

Anyway, the time comes to pic up the bike, I walk into the shed where it was stored and took one look thinking to myself " who the heck could let a bike get this bad"..... It was calling out ot be saved so save it I shall....

No fairings were attached, carbs all open to dust, bugs, and whatever else wanted to make home in those dark dry tubes.
Wiring looked like a hell of alot of burnt spaghetti with a few baked beans added to the mix....Not to mention what was connected was connected totally wrong.
The foot pegs were rooted and repaired with 1 inch box steel with the foot brake binding on the frame and the front brake facing more skyward than I would ever like to get the front wheel.

I could carry on making a list of bad things but don't want to make this boring.

A few good things were a near new rear tyre, brake linings and rotors are in really good with the master cyclinders only needed a little clean up.
The fraon has recently been bead blasted so not much prep work needed at all for powder coating.
The front end is fairly ok, might get away with the fork seals being done and some new oil but over all condition they seem pretty good. No pitting or corrosion. Also no play in the headset with only minior play in the swing arm bushes.

ok I will stop blabbing on and throw up some pics.. See below how she came to me...

**manwithav8** · 28th September 2007, 20:30

I kind of lied a little sorry. The bike had clip ons etc still bolted up but todays saw to that...

So while work was a little quiet today I jumped upon the little rev bucket and started the good old rip shit and bust.... I cleared out all that I wanted out of the way so I could dit for a while pondering on how I could attck this project.

Well I removed the clip ons which are bent to buggery and the controls are kinda naffed. I took the wiring loom right out so I could have a really good look and tested the connectors. To my suprise it is not too bad at all.

So there I was sitting with the frame holding the engine and the wheels on and then it came to me, I wonder if the bloody thing even turns over...

So why didn't you think of that while it was together you say. Well my answer to you is, even if I had of though that, nothing would have worked because the bike was wired totally wrong and by looking at it I knew there was no way it would run like that..

OK, getting back on track, I made sure it wasn't seized. Turned it over by hand while looking down the inlet tubes and it was good to see the valves opening and closing.

So next was to see if I could temporarily hook the loom up to see if I could get power and may get it turning over so I could check for spark..
Yeeaahhhh, after 2 friking hours I had the starter spining and have spark.....

So, the big test was to feed those open carbs with some ether and see if it will fire and run for a little... Bare in mind, open carbs and no ehxaust.

While you wouldn't beleive it, she fired up and ran till the ether ran out. But to my suprise it was firing on all four....

So anyway, that was my day with the fizzer 4 hundy.....

Oh and please don't ask what y plan of attack is for this project because I still haven't come up with one lol

**Paul in NZ** · 28th September 2007, 21:07

Whooo Boy.... Another FZR project... Looks pretty straight and at $150 the price is right... Let me know if I can help in any way....

**manwithav8** · 28th September 2007, 21:19

lol thanks Paul..

You yourself know how a digital camera makes things look 10 times better than they are.

I am waiting to see if the previous owner has the mirrors and front indicators or not.

Tossing up whether to keep it totally standard or build it with what I can etc. Was toying with the idea of maybe going for a little streetfighter look with it but want to try my hand at fibreglass work.

Will wait and see if she has all the parts I need before I go with a plan. If I do go the streetfighter look, I will ensure it can be returned to standard trim though..

**riffer** · 28th September 2007, 21:26

Wow. Chain could do with some oil

Seriously though. Congratulations. A worthy bike for a resto project. I shall follow this thread with interest.

Look to Paul in NZ's thread for ideas...

**merv** · 28th September 2007, 21:31

Originally Posted by riffer

Wow. Chain could do with some oil

Agreed, how the hell could that be so short of lube its gone that rusty.

Great project all the same.

**manwithav8** · 28th September 2007, 21:42

Good spotting guys, lets say I didn't piss around getting that off... The sprockets match the chain so they are going aswell...
Will be over with the fizzer on Sunday to check how well the valves are sealing.. The good old kero trick lol

**manwithav8** · 4th October 2007, 19:12

Well all seems well with the engine so I am not going to muck around with it.

Haven't been able to take anymore pics at this stage and I will be taking the next week off work so nothing will happen with the fizzer..

What I have done lately was removed all the brakes. I have pulled the calipers down ofr a good clean up and repaint gloss black. There was only one piston that hadn't seized and didn't need compressed air to get it out of the bore.
I called into the yama shop in wanga's for a price on piston and seal kits for the 400hundy and OMFG!!!!!!!! I will be painting and reassembling with fingers crossed that when bled there is no leak.

Here are the prices-----

Piston $167
Seal $57.95.

So there you have it, a total cost of $449.90 per caliper. Yes they are a 4 pot caliper and guess what, dual brakes on the front so all up to rekit the front end will cost $899.80.

So looks like I will be doing a whole lot of polishing, a a little painting and a shit load of praying that the old seals and pistons will hold together.

I am painting the calipers black because I am thinking of doing a black and alloy coloured theme of some sort..

So, who wants to cross their fingers with me in the hope that the brakes will go together and be ok????