Preparing the FZR 600R for the spring and beyond.

      Well, still awaiting a project to come into sight. So while the hunt continues - I may have a lead on a Harley Iron Head 883 - depending on a lot of variables - price being the main one.  I am going to get my much loved FZR back on the road.

     So it needs a good going over, fuel system and a fresh battery are the top two jobs. So fuel system first. The tank needed draining, luckily I love the taste of petrol - trusty syphoning tube and a petrol can in hand, the tank was drained quickly enough, and the lingering taste of petrol stayed with me for the rest of the day. Once tank empty a retaining bolt and swivel bolt removal and the tank lifts off.

     This exposes the airbox, my first Doh! moment. I lifted the box off, it felt a little reluctant - so i applied a little more force to it, and off it popped. Unfortunately the carbs came with it! Forgot to undo the circlips that secure the airbox to teh carbs! Still needed to refresh them - at least I justified my rush of blood. So to put them back on...... A nice new set of shot filled hammers that had been bought for Valentines day, came onto use. Circlips loosened to facilitate a nice refit, i eased the carbs back on to the engine, gently tapping them back, then a rash hard tap and carb number 3 intake cracked! A pice popped off, luckily somewhere into the garage and not into the engine! FFS i whispered. First repair job, to fixe the crack and chipped carb intake.  As can be seen in the picture, the use of expoxy resin and time mended the chipped intake. Also had the presence opf mind to stop drillthe crack! Filled that as well. refitted as seen, here.

The repair can be seen on the 3rd intake in at the 6 o'clock position. Am quite proud of the work and  added a new skill to boot. The carbs move freely and a good dose of WD-40 down each intake just to help.

The onto my original take, clean out the tank and fuel filter inside it.

The fuel pump and filter come of the tank easily, undoing 6 retaining bolts and off it came. The took it apart, removing the rubber tubing and filter for a clean, At this point, a small circular piece fell out of the assembly. I was confucse as i could not locate where is originated from. Was t from inside the cage filter? I searched my manuals and the interweb - to no avail. In a last ditch attempt to find it's origin I googled the wording on it, from AEG. A sigh of relief later - turns out it's a micro chip from the 90's that were glued over a bike to ensure security, happy days, it's not a part! 

So the  filter, seen at the front lower part of the assembly, and the rubber tubing were remover and cleaned. The tubing shortened a little as the ends were granulating. Then the piece put back together, minus the microchip. It is now ready for attaching back on the tank.

The tank is clean inside, so no real work there, just some blistering of paint on the base, where the fuel pump / filter assebly reattaches. Looks wors in the picture than in reality. But will clean it up with a hard brush and see what lies below. I think it will be good, as stated, the inside of the tank is clean as a whistle. So here is hoping no more hiccups on this part of the clean up.

     Next up will be cleaning out the vaccum hoses and overflow tubes. Then plugs, oil filters and oil change to get things on track before battery and starting up. Then the MoT.....

Tools then project

      Having left the states, leaving behind a lot of tools sand selling my beloved Sheldon Lathe and Wells Index Mill - I found myself emoty, nothing to do or make, or in the words of my very good friend - 'Dink with'.

Moping around, looking at my yellow FZR 600R, I know it needs a full service, battery and the fuel system draining, my heart was not into it, the tooless garage moking me,

     My gorgeous wife, then, from the blue, bought me this:

     A Boxford Model A, in my favourite - SAE - it runs sweet as a nut, and will be levelled this week. Joy of joys - now all i need is the steady rests and to pick up a 4-jaw chuck at some point, but there are ways around that.

     Now my FZR is looking more tempting, a fettle over the winter months, prehaps a new exhaust too, all this getting me back into the stride ready for my new project when i find it. Until then - this gets a fettle: 

     It was a write of and rebuild from scratch, and was my first real bike restoration / rebuild. Can never part with it, and polish it occasionally, emotionally attached as i always do to my mechanical stuff.

Back in the UK, now the itch needs scratching again......Thank you Barry

      So, been back in the UK now for 3 months, got the house almost sorted, tools arrived back from overseas safely, unlike some of our belongings. Still have a pang of regret over selling up on my KZ650, lathe and milling machine. But ever the optimist i still have my spanners and tools. The journey begins again. Looking at projects whilst sorting a few things, and generally pottering in the garage. Then I visit the dad-in-law, takes me into his garage and presents me with a large box. "Don't open it 'till you get home" he says. 

     Drinking up the tea, leaving and driving like I stole it, i get home and 2 minutes with a box cutter, the gift is revealed, and it is not quite my genre, but gorgeous and now the creative juices and lists are growing. It is a carbon fibre, to gorgeous to paint, but who knows.

     Need a donor bike first, undecided - should i go modern and dress up as retro, giving the apearance of a classic witht he advantages of modern technology or just gro straight old school?

     The quandry begins.......Will keep y'all posted, but this is the look i am going for:

     The costs to get this done true to original are prohibitive, so am looking to pay homage to the era rather than restore / create a true period racer. Donor will be something along the lines of  CB / GS / Z  or the like, if one comes up at the right price and location. 

      Will see what happens over the next few weeks and months.

     And, as you can see, may have to be creative with exhaust routing and fairing manufacturing. The tank should be easy enough to do, the rest....

     Right, am away to scroll my way through eBay, marketplace, Gumtree and local ads to see what comes up, The itch needs attending too, but not rushing into it.

     Check back for the occasional updates until I find the project. 

A New Hope (no not star wars)

     Well, I may have an opportunity in October to get my bike home. Ii is a slim opportunity but one I am going to grasp.
     So i may have my cafe racer project by November this year again.

     In the mean time i will need something else to do......hmmmmm

Parting Ways...........

     Due to export / import costs, it is not practical for me to take my bike home to the UK. Unless I find a way, I am selling my much loved project before my return to to Scotland.
     This is a sad day, needs must when the devil is driving. If you are interested, drop me a line.

     Will start another project when I find one back home in Scotland.

My first build, FZR600R in yellow.

    As I am away at home in the UK at the moment, in between various jobs to be done, I got my loved 600 out for a wash and refresh.
    It's a light tuned FZR600R. The paint job was born, like most of my work from costs and necessity. SAR yellow,  which lead to the choice of Camel Racing Rossi colours. Lots of fun and can't wait till next spring, 2 bikes with different characters to choose from.

Seat Unit Modifications before paint......

     Before I get my 'tins' painted, there is a modification I need to do. So as not to spoil the lines of the tail unit. Just so as not to spoil the tail lines, a little like the bike below:

 

     The thing is, I hate paying too much, a modified rear seat pan is around double that of the one I have, the tail light is an LED item from eBay, costing $6.00 including delivery. The pipe was the same from home depot. A couple of thinking days later, some measuring and more thinking the shopping list was compiled. Fiberglass repair kit, 2" PVC pipe and a 2" PVC pipe connector to make and recess the light. 

     Off to the late I goes, opening one side of the connector to accept the tail light mount and to cut and open out the PVC pipe to accept the lens. The two parts then glues together ready for shaping to fit the tail unit. Once fitted the unit center line will be marked, the pipe shaped to the correct contour and then rough mounted. The initial mounting enabling the positioning and marking of the hole to be cut in the seat unit (I know - very sweaty moment and large cojones required for the cut).

     Progress so far has been made, just the shaping and cutting to go. The some light gluing, fiber-glassing and lots of sanding to get the smooth lines I desire.  Once fitted - it's off to the paint shop!