1991 Yamaha fzr400rr

Discussion in 'Other Projects - Other Bikes (non 250's)' started by kiffsta, Feb 10, 2021.

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  1. kiffsta

    kiffsta Senior Member

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    Picked up a non running 1991 fzr400 , aregghhh bloody carbs were shocking , all 4 slide holders were broken , lucky I found some spares

    tomorrow she is going to burst into life , well I hope it does


    C772F36E-D416-4DFA-AAA6-C94D5BCE5504.jpeg AB652BB5-5941-4841-B667-9490972EC832.jpeg F93CE89A-DAA7-46FB-A723-D73C0FCA6944.jpeg
     
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    kiffsta, Feb 10, 2021
    #1
  2. GreyImport

    GreyImport Administrator Staff Member The Chief Contributing Member

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    Track bike! :crazypilot:
     
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    GreyImport, Feb 10, 2021
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  3. grcamna5

    grcamna5 Active Member

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  4. kiffsta

    kiffsta Senior Member

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    No chance of starting , she would turn 1/4 of a revolution then lock up , no plug in number 4 so we pulled the engine out and popped the head off , have you ever seen something like this ?
    2210D127-AB68-4A4C-AF9E-C7A0889BAB2B.jpeg 98580931-D566-468B-B8BC-76C510CBCB59.jpeg 34973831-2BF4-45B5-B331-22DB1890E190.jpeg

    tree sap ?
    Off to the machinist for a birthday , will try and save this one
     
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    Last edited: Feb 11, 2021
    kiffsta, Feb 11, 2021
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  5. jmw76

    jmw76 Well-Known Member

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    Thats a new one on me.
     
    jmw76, Feb 11, 2021
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  6. Murdo

    Murdo The Good Doctor Staff Member Contributing Member Ride and Events Crew

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    Dried up fuel, probably from a leaking needle.
     
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    Murdo, Feb 11, 2021
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  7. Jethalter

    Jethalter Well-Known Member

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    it was just attempting to make a mould of the top of the piston for you to use in the casting process :p
     
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    Jethalter, Feb 11, 2021
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  8. kiffsta

    kiffsta Senior Member

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    While the head was off , I have it a good clean , will get my machinist to fit new valve steam seals and see about opening up the ports a bit

    A4845E96-988B-4570-A08D-0C39445CD1DF.jpeg 9D4C3FA7-BF33-4DB1-B4B3-B39059E689A5.jpeg
     
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    kiffsta, Feb 11, 2021
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  9. Linkin

    Linkin The Mechanic Premium Member Contributing Member Dirty Wheel Club

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    That blasting you do never ceases to amaze me. A worthy project bike as well.
     
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    Linkin, Feb 11, 2021
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  10. ruckusman

    ruckusman White Mans Magic Master Premium Member Dirty Wheel Club

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    I AM SO JEALOUS RIGHT NOW
     
    ruckusman, Feb 12, 2021
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  11. thebeefsalad

    thebeefsalad Well-Known Member

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    How do you protect the inside of the head when you blast it? I was half tempted to have mine blasted but the company said "nope! beads will be hard to get out from hard places in the head"
     
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    thebeefsalad, Feb 12, 2021
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  12. maelstrom

    maelstrom LiteTek Staff Member Premium Member 250cc Vendor Contributing Member

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    I have been using silicone plugs and aluminium tape, works well for me. The company that did the wet blasting was very impressed with the tape and asked me where I got it from. Unfortunately, removing the tape is a bit tedious. I also seal all threads with set screws. All about the preparation.
    With my head I was mostly concerned about sealing off the water jacket. I used a high pressure water blaster, detergent and an array of brushes to clean and wash after getting the parts back.

    Here is a carb I prepped for dry blasting.
    [​IMG]
    and here is how I originally prepped my head for dry blasting and painting. No such word as "can't".
    [​IMG]
     
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    maelstrom, Feb 12, 2021
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  13. kiffsta

    kiffsta Senior Member

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    I use a flush tank, then compressed air. Finally I use a vibrating table to get the remaining bead out
     
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    kiffsta, Feb 12, 2021
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  14. thebeefsalad

    thebeefsalad Well-Known Member

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    Aluminum tape: would that be the HVAC variety or telecom flavor? I feel like i'd have to spend a small fortune in grub screws to blast mc22 cases
     
    thebeefsalad, Feb 12, 2021
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  15. maelstrom

    maelstrom LiteTek Staff Member Premium Member 250cc Vendor Contributing Member

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    I don't know, just foil tape. In some places I doubled up on the thickness. Grub screws are very cheap. I just bought a hundred or so.
     
    maelstrom, Feb 12, 2021
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  16. maelstrom

    maelstrom LiteTek Staff Member Premium Member 250cc Vendor Contributing Member

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  17. kiffsta

    kiffsta Senior Member

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    Wow , that is impressive

    I have been having troubles finding valve stem seals , I called a Russell from bk performance and he has 10 Athena top end kits in stock, I’m going to pick one up on Monday

    then it s off to the machinist
     
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    kiffsta, Feb 12, 2021
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  18. gregt

    gregt Well-Known Member Premium Member

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    Both the 400 and 600 need the bottom of the inlet ports filling. Basically you concentrate the flow in the top half of the ports.

    If you're not going to do the thing the whole hog, just clean up the first 15-20mm under the valve head.
    Leave the inlet tracts as cast. they're actually too big and cleaning them up makes it worse.

    Be aware that some aftermarket listings for stem seals are actually wrong. I've been caught by this a couple of times.
    For the 400 and 600 i now use OE seals from the local agent.
     
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    gregt, Feb 12, 2021
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  19. maelstrom

    maelstrom LiteTek Staff Member Premium Member 250cc Vendor Contributing Member

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    I had some Chinese ones but chose not to use them and went with OEM also, mine from Impex. Speaking of inlets, I'm making some manifolds for a customer to use 1WG rubbers on the 3TJ as we speak. This is just a test piece to check my dimensions.
    manifoldTest.jpg
     
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    maelstrom, Feb 12, 2021
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  20. Frankster

    Frankster Grey Pride...Adventure before Dementia Staff Member Premium Member Ride and Events Crew

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    Interesting, but not unexpected, the comment about dropping the EXUP for racing. I think @GreyImport discarded the EXUP on his FZR drag bike. FZR400 dyno sheet...65hp at the rear wheel...that's stout.

    FZR400EXUP.jpg
     
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    Frankster, Feb 12, 2021
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