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Posted: **Fri Jun 24, 2005 6:06 am**

John has asked me to build an engine for him and I just went over to Seattle the other day to pick it up from Forward Air. <img src="http://img.photobucket.com/albums/v291/ ... GP2912.jpg" style="border:0;"/> And the unwrapping... I think John must have used 10 tiedowns <img src="http://img.photobucket.com/albums/v291/ ... GP2913.jpg" style="border:0;"/> <img src="http://img.photobucket.com/albums/v291/ ... GP2914.jpg" style="border:0;"/> All's wonderfull so far. Now when John first approched me about this project, he told me that the motor came from some folks in Tennasee that were involved in building motors for Legends cars. Bob (the straight up Geek) also had some dealings with these folks that came to a less than satisfactory conclusion.... At any rate John said the motor had developed an ugly noise in the bottom end that sounded like maybe a rod or a collapsed piston.... Ok, We'll see what the trouble is. When I opened the cam box I found that the cam cap bolts were in the incorrect locations so that the long ones were protruding into the intake runners and that there was what looked to me like evidence of oil starvation on the cam journals So I take the head off and find.... <img src="http://img.photobucket.com/albums/v291/ ... GP2916.jpg" style="border:0;"/> <img src="http://img.photobucket.com/albums/v291/ ... GP2917.jpg" style="border:0;"/> <img src="http://img.photobucket.com/albums/v291/ ... GP2915.jpg" style="border:0;"/> <img src="http://img.photobucket.com/albums/v291/ ... GP2922.jpg" style="border:0;"/> <img src="http://img.photobucket.com/albums/v291/ ... GP2924.jpg" style="border:0;"/> <img src="http://img.photobucket.com/albums/v291/ ... GP2925.jpg" style="border:0;"/> These are pics of the #2 cyl on the head. Been bangin a bit... So I look in the hole and I find This..... <img src="http://img.photobucket.com/albums/v291/ ... GP2918.jpg" style="border:0;"/> <img src="http://img.photobucket.com/albums/v291/ ... GP2919.jpg" style="border:0;"/> <img src="http://img.photobucket.com/albums/v291/ ... GP2921.jpg" style="border:0;"/> Hmmmmm, sez I. This is not so wonderfull. But it's fixable. I gave Bob a call to see if he had any spare Wiseco 1040 pistons and he does. Same casting number and all. Then I look over at # 3 and damned if there isn't a crack, or what looks very much like a crack in that piston. I also looked at the top of the block and there are machine marks from decking the block.... Ok....so the picture is becomming a little more clear in my mind as to what these Yo Yo's in Tennesee did. I pull the block to find that there are TWO steel base gaskets under there and only one of the four Orings are there. When I pulled the head I found that they had used a gasket that blocked 7 of the 10 water passages from the block to the head per cyl..... Not a good thing. So I go send pics of this to John... Start pulling piston pins and they sure are tight... #2 rod little end is a nice golden color....Uh Oh... Well...Press on and split the cases. The inside main (14mm) bolts were WAY THE FOOK TOO TIGHT!!!!! Lots of evidence that these guys didn't own a torque wrench. But when I got the crank out, Here's what I found... <img src="http://img.photobucket.com/albums/v291/ ... GP2929.jpg" style="border:0;"/> <img src="http://img.photobucket.com/albums/v291/ ... GP2930.jpg" style="border:0;"/> <img src="http://img.photobucket.com/albums/v291/ ... GP2931.jpg" style="border:0;"/> That is the center main bearing. This is a representative look at one of the other mains ... <img src="http://img.photobucket.com/albums/v291/ ... GP2932.jpg" style="border:0;"/> Now...I need to Box it all up and keep it all organized till new parts get here. <img src="http://img.photobucket.com/albums/v291/ ... GP2926.jpg" style="border:0;"/> Oh a better note though...John had mentioned that the tranny did shift very nicely. When I got there I found a nicely back cut gearbox. But oddly enough...onle on the dogs. Not the slots... Also (and I particularly enjoyed this part) the only gaskets that I found in this engine were the cambox cover, head and base gaskets. ALL other gaskets were missing and the builder has used RTV ....Lots of RTV. I have yet to look at the oil pump and take the head apart and look at the valves so we'll see what we find when we get there. I have not had time to measure anything at this point save the crank which I found that the center main bearing journal is .001 undersize from the rest..... On a side note.....(and I liked this one too) normally the rods are marked or coded if you will, to indicate the fit (bearing) with the crank and the crank is marked as well....Not on this motor. Those markings had been ground off of the rods and the numbers 1 thru 4 had been steel stamped there instead. Oh Joy!!!! Now we'll get tt plastigage everything. Not that big of a deal because I'd have done that anyway<img src=http://img.photobucket.com/albums/v209/ ... Cheers.gif ALT=":cheers"> More to come........ Jim <img src="http://img.photobucket.com/albums/v209/ ... Cheers.gif" style="border:0;"/> <img src="http://img.photobucket.com/albums/v209/ ... states.gif" style="border:0;"/> Hey Kid...Is my taillight working?Edited by: <A HREF=http://p072.ezboard.com/bexupbrotherhoo ... cer1951</A> at: 6/24/05 4:19 am

Posted: **Fri Jun 24, 2005 9:07 am**

Interesting picy's Jim - not too many '89's with YZF cranks either, quite the combination. I wonder if that engine build was an excercise in how to "Chevrolize" an FZR???? Hope that crank is save-able, 'cause that's one part I don't have any spares for. Good stuff though <img src=http://img.photobucket.com/albums/v209/ ... Camera.gif ALT=":camera"> <img src=http://img.photobucket.com/albums/v209/ ... Camera.gif ALT=":camera"> Genisx1AtYahooeyDotCommaMommaEdited by: <A HREF=http://p072.ezboard.com/bexupbrotherhoo ... upElvis</A> at: 6/24/05 5:48 pm

Posted: **Fri Jun 24, 2005 5:05 pm**

Great posting, Jim. Really looking forward to seeing this project progress. John - you come out of the fetal position yet? <img src=http://www.ezboard.com/images/emoticons/laugh.gif ALT=":lol"> Don't worry bud, everything will be fine. At least you still have bike(s) to ride while this one is getting doctored. Nate - 87 FZR1000 <img src="http://img.photobucket.com/albums/v485/ ...  Have you seen my fairing? Who cares...I got new ones!!!

Posted: **Sat Jun 25, 2005 12:36 am**

Did ya'll see all the pretty colors on all the parts and the sparkly glitter in the block and head! Bob told me about the tenn. folks<img src=http://img.photobucket.com/albums/v209/ ... ock_On.gif ALT=":rock"> Freelance Bodyman I be ridin the Cali Bay Area '88 & '89 FZR1K BOTH ARE ONLY HALF NAKED NOW!!!

Posted: **Tue Jun 28, 2005 12:20 pm**

good pics jim - thanks for taking this project on. I have a comfy feeling knowing that between you, bob and tim...we'll come up with good donor parts without forking over full price yamaha pieces. with the gee pee fast approaching theres plenty of time to mull things over... -John  <img src="http://img.photobucket.com/albums/v485/ ...   <a href="http://img.photobucket.com/albums/v206/ ... cement.jpg" target="top">1995 FZR1000</a>  <a href="http://img.photobucket.com/albums/v206/ ... 00x600.jpg" target="top">1990 FZR1000</a>  <a href="http://img.photobucket.com/albums/v206/ ... resize.jpg" target="top">1990 FZR1040</a>

Posted: **Tue Jun 28, 2005 10:40 pm**

jeez...looks like they did a worse job than I would've done....jeez jeez jeez....uncle fockers Nbot '94 Fizzer Litre This is your sig on drugs....

Posted: **Wed Jun 29, 2005 6:54 am**

Yea John...I'm thinking about bringing this crank along so you gys can see it...I'll for sure bring the center bearing and a rod and the hammered piston... Jim <img src="http://img.photobucket.com/albums/v209/ ... Cheers.gif" style="border:0;"/> <img src="http://img.photobucket.com/albums/v209/ ... states.gif" style="border:0;"/> Hey Kid...Is my taillight working?

Posted: **Thu Jun 30, 2005 2:37 am**

Oooooohhhh, us Gee Pee guys get a show and tell! Thanks Jim, for bringing it along for us to see! The talk will definitely be John's motor instead of your bar tab!!!!!!!!! Darn, should I've had mentioned that<img src=http://img.photobucket.com/albums/v209/ ... Cheers.gif ALT=":cheers"> Freelance Bodyman I be ridin the Cali Bay Area '88 & '89 FZR1K BOTH ARE ONLY HALF NAKED NOW!!!

Posted: **Thu Jul 28, 2005 8:14 am**

I wish I had a "Jim" in my neck of the woods, to help me with all of my unanswerable questions. Sometimes you just need an honest professional with lots of experience with a FZR. I remember when I first got my bike, I searched for the best person/place to have some items like the carb & such looked at. The best I came in contact with was the "5 STAR RATED YAMAHA DEALER" ??! What a load of S#%@ they were. After 1 month when they finally got to my bike, the mechanic told me that the top end of my motor was shot & that I should just dump my bike as quickly as I could. The first thing I did after that was but newer "untouched" carbs & imagine that...Everything was fine again. HMMNN?

Posted: **Mon Aug 01, 2005 5:06 pm**

Well...I just returned from the secret FZR parts stash (Thanks Bob...) with a block, a couple of pistons, some pins and some rods.... I had measured the block that came from John's motor and it was 3.150 to 3.144 from the base to deck....006 taper and .035 to .041 undersize..... <img src=http://www.ezboard.com/images/emoticons/mad.gif ALT=">:"> But now we have what we need to proceed. More to come Jim <img src="http://img.photobucket.com/albums/v209/ ... Cheers.gif" style="border:0;"/> <img src="http://img.photobucket.com/albums/v209/ ... states.gif" style="border:0;"/> Hey Kid...Is my taillight working?

Posted: **Tue Aug 02, 2005 1:34 am**

<blockquote>Quote:<hr>secret FZR parts stash<hr></blockquote> Top secret! Shhhhhhhh................... It's all worth it for a few more pics I'm sure... Genisx1AtYahooeyDotCommaMommaEdited by: <A HREF=http://p072.ezboard.com/bexupbrotherhoo ... upElvis</A> at: 8/1/05 11:37 pm

Posted: **Tue Aug 02, 2005 8:53 pm**

Well...The crank's toast cracked about 3/4 way around the center journal .003 runout at the center journal. It took a bang Anyone have a decent crank for John's motor?? Jim <img src="http://img.photobucket.com/albums/v209/ ... Cheers.gif" style="border:0;"/> <img src="http://img.photobucket.com/albums/v209/ ... states.gif" style="border:0;"/> Hey Kid...Is my taillight working?

Posted: **Tue Aug 02, 2005 9:40 pm**

<blockquote>Quote:<hr>It took a bang<hr></blockquote> And I'll bet the crank giving up was the last noise heard when it stopped. My guess is those pistons had been hitting for a while....... So, ummmmmm, we'll tear into the last case and see if the cranks good in that one <img src=http://img.photobucket.com/albums/v209/ ... ng_sad.gif ALT=":sad"> . Genisx1AtYahooeyDotCommaMomma

Posted: **Wed Aug 03, 2005 7:13 am**

You Sir, are the MAN!!! Jim <img src="http://img.photobucket.com/albums/v209/ ... Cheers.gif" style="border:0;"/> <img src="http://img.photobucket.com/albums/v209/ ... states.gif" style="border:0;"/> Hey Kid...Is my taillight working?

Posted: **Sat Aug 06, 2005 1:59 pm**

So I had to tear into yet another FZR case, and I kind'a wanted to see how long it would take. The pics should be time stamped to illustrate that - keep in mind I wasn't racing here, just moving through the job at an appropriate pace so as not to damage anything. I was surprised to find it only took about an hour and a half to get the crank out (with the head already off). I guess just for the entertainment of those facing a trans R&R or other case splitting excersises, It can be done relatively quickly - and sure doesn't mean the end of your bike if you do have to split the cases! Ok, enough out'a me, lets do this - <img src="http://img.photobucket.com/albums/v208/ ... CN0151.jpg" style="border:0;"/> <img src="http://img.photobucket.com/albums/v208/ ... CN0152.jpg" style="border:0;"/> <img src="http://img.photobucket.com/albums/v208/ ... CN0154.jpg" style="border:0;"/> <img src="http://img.photobucket.com/albums/v208/ ... CN0155.jpg" style="border:0;"/> <img src="http://img.photobucket.com/albums/v208/ ... CN0157.jpg" style="border:0;"/> <img src="http://img.photobucket.com/albums/v208/ ... CN0158.jpg" style="border:0;"/> <img src="http://img.photobucket.com/albums/v208/ ... CN0159.jpg" style="border:0;"/> <img src="http://img.photobucket.com/albums/v208/ ... CN0160.jpg" style="border:0;"/> <img src="http://img.photobucket.com/albums/v208/ ... CN0161.jpg" style="border:0;"/> And there 'Ya go, crank and rods out and checked. Looks like John got lucky this time, everything looks good to re-use! <img src=http://www.ezboard.com/images/emoticons/happy.gif ALT=":D"> Genisx1AtYahooeyDotCommaMommaEdited by: <A HREF=http://p072.ezboard.com/bexupbrotherhoo ... upElvis</A> at: 8/6/05 12:08 pm

Posted: **Sat Aug 06, 2005 2:34 pm**

Woot!! You no longer have a wonky crank, John. <img src=http://img.photobucket.com/albums/v209/ ... e_poke.gif ALT=":poke"> <img src="http://img.photobucket.com/albums/v209/ ...  There are some who call me........Tim? Top Speed = Mach 0.197 or so...  1994 FZR 1000 <img src="http://img.photobucket.com/albums/v209/ ...

Posted: **Sat Aug 06, 2005 3:41 pm**

Yea...cause he Damn shore did!!! Jim <img src="http://img.photobucket.com/albums/v209/ ... Cheers.gif" style="border:0;"/> <img src="http://img.photobucket.com/albums/v209/ ... states.gif" style="border:0;"/> Hey Kid...Is my taillight working?

Posted: **Sun Aug 07, 2005 1:08 am**

That's 1 lucky homie that got served on that shizzzznit<img src=http://img.photobucket.com/albums/v209/ ... ock_On.gif ALT=":rock"> Freelance Bodyman I be ridin the Cali Bay Area '88 & '89 FZR1K BOTH ARE ONLY HALF NAKED NOW!!!

Posted: **Sun Aug 07, 2005 1:46 am**

jim earlier wrote - <blockquote>Quote:<hr>When I opened the cam box I found that the cam cap bolts were in the incorrect locations so that the long ones were protruding into the intake runners and that there was what looked to me like evidence of oil starvation on the cam journals<hr></blockquote> How do we ensure that oil pump is indeed working and supplying enough oil to the cam journals to avoid failure? and nice pics! thx -John  <img src="http://img.photobucket.com/albums/v485/ ...   <a href="http://img.photobucket.com/albums/v206/ ... cement.jpg" target="top">1995 FZR1000</a>  <a href="http://img.photobucket.com/albums/v206/ ... 00x600.jpg" target="top">1990 FZR1000</a>  <a href="http://img.photobucket.com/albums/v206/ ... resize.jpg" target="top">1990 FZR1040</a>

Posted: **Sun Aug 07, 2005 8:32 am**

We'll put the pump together and blow all the passages. Check the output of the pump at the end of assy and all the caps will be back in the correct locations... It'll be fine John Jim <img src="http://img.photobucket.com/albums/v209/ ... Cheers.gif" style="border:0;"/> <img src="http://img.photobucket.com/albums/v209/ ... states.gif" style="border:0;"/> Hey Kid...Is my taillight working?

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John's new engine

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