Graeme's FZR400 EXUP (3EN1)

[graeme]

After bombing around on an Honda VT250FG for the past couple years I decided it was time for something with a bit more grunt, and a lot more grip. And here she is...



I've got a bit of work to do, so I'll be updating this thread as I go. At this stage I just want her running well for everyday use.

First impressions:

The Good:

• Bodywork is in pretty good condition
  She handles beautifully
  New tyres (Kenda, but I'll think they'll do for now - any opinions?)

The Bad:

• Orange screen (I might get used to this )
  No indicators
  Hole in the exhaust
  Front brake rotors are warped (pretty badly I think, whole front-end pulses)
  Hard to start when cold
  Hard to pull off in 1st without stalling
  Not much pull when accelerating
  No top-end (she's maxed at 120kph)
  Lots of (what I think is) cam-chain noise
  I can hear (and feel) a bit of a knock in the engine
  I can feel fine vibrations through the chassis at low rpm (especially through my legs)

I welcome any comments/info about any of these things!

Tomorrow I'm getting those fairings off and having a look at those carbs...

Oh... and taking more pics

[Evilchicken0]

Take the exup cover off and see if it's moving. If it's seized that might be the top end and starting problem.

But it looks ok ... that screen looks like a 3en2 one because it extends beyond the fairing. I think Powerbronze do a 3en1 screen.

[Taggyd]

I've got a set of rotors from a broken bike, was running and stopping well before i split it if you're interested.
The cam noise could just need a little help to click to the next ridge. GENTLY put a screwdriver in to push the adjuster after taking the bolt out, may just pop it too the next one, but don't ram it in!
Might even have a set of indicators for the front but not sure what is in the shed!
Also got a dark screeen for the 3en1 in good condition!
pm me if anything is of interest!
taggy

[graeme]

Hmmm, this is turning into a bit of a workshop thread...

The fuel-pump was making quite a racket, so I got the tank off and had a look - it seemed to be fine (other than being cable-tied to the bottom of the tank), but I opened it up just to be sure. Fuels lines also a bit perished, I'll replace them.

Thanks Evil, I moved onto the EXUP valve... which was well seized. Took me and a mate about 20 minutes of hammering, levering and twisting, but it came out... properly caked in 'stuff'. Cleaned up OK, but I think it's missing a bush and spacer. Good news is the servo still appears to be fine. Hopefully that sorts out the lack of top-end.

Got the carbs off and stripped - they all look good except for the far, right one - it's got the wrong diaphragm (slightly too tall and wide). I'll try track down a new one.

Next, I'd like to get the tappet-cover off and check those valves and the cam-chain - thanks for the info Taggy, and for the parts offer, I'm in South Africa, though, so might be difficult (err, $$$) shipping them here... but I'll keep it mind :)

Once I've got her back together I'll snap a couple of proper pics!

[Evilchicken0]

Have a look for a 3he 600 (the cheap option), the forks will bolt in and the discs will be 300mm
A Yam front end will probably drop into the frame - a YZF750 might be a reasonable chioce but ditch the calipers.

[Taggyd]

missed the SA bit! oh well! shame cos i got the inners of an exup sat in the shed!

[graeme]

Quick update and 2 pics...




Checked valve-clearances - exhaust are all in spec, but almost all the intakes are marginal to too small a gap. Still need to adjust that cam-chain (thanks for info Taggy).

Got a long list of things to get through... but hoping to start her up this weekend and see how she runs with the carbs clean and the EXUP valve sorted

[Pleiades]

Before you replace those rotors, take a look at this article - http://www.stoptech.com/tech_info/wp_wa ... disk.shtml. An interesting take on the warped rotors thing.

[graeme]

Thanks Pleiades, that made for some interesting reading...

[mike1964]

Like the colour scheme, but the screen has got to go........

Keep up the good work.....