The rebirth of a 1990 fzr1000

[Stig]

There’s a way of arranging the rubbers so the screws face the headstock AND keeping all the original notches. I’ve done it to my own
Easy way is to set the rubbers on the table with notches aligned with the carb notches, then flip and arrange the clips to suit

[bunk]

There’s a way of arranging the rubbers so the screws face the headstock AND keeping all the original notches. I’ve done it to my own
Easy way is to set the rubbers on the table with notches aligned with the carb notches, then flip and arrange the clips to suit

Aah ok now i understand what you were getting at. I should easily be able to do that with the engine on the bench.

Here's a little organization in the midst of chaos.

[bunk]

Well i havnt had to go backwards assembly wise yet, but i did have to stop here because i dont have a worthy adhesive to hold onto those little fingers on the gasket. All of them are bent so i need to buy something to hold them in place.



Once im done there i'll machine up some rings to stretch out the rubber diaphram so i can easily glue them back in place. That will likely be monday.

[bunk]

I ended up carefully using a mini torch to heat up the float bowl gasket so the little tangs would stay lined up. Then it was time to figure out something for the diaphrams. I measured the small diameter of the groove and came up with 2.670 so i intended to machine up a ring that was 2.700. I started looking for material and ran into some rems that were 2 3/4 (2.750) and the stretch of the diaphrams felt perfect so all i did was clean up both ends, and do a scotchbright debur so the corner will hold better. I'll assemble everything tomorrow, then get the engine on the bench.

[bunk]

Got the engine up and cleaned it up some, did all the o-rings for the water inlet/pump and outlet. They all had huge flat spots on them. Monday i'll likely start checking valve clearances. Currently looking for reasonably priced silicone hoses, but have not found them yet.

[bunk]

Been working on it here and there, wheels are sanded to 240 now and only going to 400. My feeler gauges are too wide to get to the center intake but i think im fine based on the average of the rest, except for cylinder #2. I have to order a few more o-rings and a cam cover gasket tomorrow so i have time to double check and inspect that tight valve before i seal it up.

[creedxup]

Get some feeler gauges that fit the centre valve.
One of yours is at 2 thou, one of the others may be 0, then it won’t start, have no power and you’ll have to do it again

[bunk]

Get some feeler gauges that fit the centre valve.
One of yours is at 2 thou, one of the others may be 0, then it won’t start, have no power and you’ll have to do it again

It ran, but im hearing you. I got time and i dont want to be pulling cams with it in frame.

Just be aware, this engine only has 14k on it.

[creedxup]

Clearances are first due at 16k mine at 16 were real tight.

When it gets hot they close right down , it loses power and is hard to start hot.

Go bigger clearance, it won’t rattle.

You can do the cams with the engine in the frame but, it’s fiddly.

[bunk]

Clearances are first due at 16k mine at 16 were real tight.

When it gets hot they close right down , it loses power and is hard to start hot.

Go bigger clearance, it won’t rattle.

You can do the cams with the engine in the frame but, it’s fiddly.

To me thats a indicator of stretched valves.

Im of the belief that there is no better builder than the factory, so if the rest of the valves are in spec im leaving it alone. Im going to get skinny feeler gauges tomorrow.

[creedxup]

The valves do stretch (in a way) they hammer themselves into the valve seat and deform which decreases clearance.
The centre valves are at a more acute angle and wear differently to the outside 2.

[bunk]

The valves do stretch (in a way) they hammer themselves into the valve seat and deform which decreases clearance.
The centre valves are at a more acute angle and wear differently to the outside 2.

Well i shall find out today if the centers are a issue.

[creedxup]

[bunk]

Still gonna send it !

Also remembered to look the chain over. Looked at the tight #2 intake lobe and it looks like all the others, nothing funky going on.

[creedxup]

All looks good

I’m an Aircraft Engineer, so I would always advise on the side of safety and/or not doing a job twice (if at all possible)