Tearing Down A Vintage Superbike Engine | FZR1000 Restoration - EP13

[@karlvanboxel561]

I have seen cams snap if the caps aren’t released evenly. I think they might be chilled cast iron which r much easier on the buckets 😊

[@KensWorldRestorations]

I saw it happen once too...still cringe every time I think about it.

[@karlvanboxel561]

If the clearance is too tight u can grind them down on an oil stone I used a ball bearing that fitted in the bucket part of the shim measured it stuck it in the shim and measure both then subtract ball diameter then u have the new shim thickness

[@KensWorldRestorations]

I've struck it lucky with a nearby shop who has spare parts - and oddly hundreds of shims. He's got the head and is going to be machining all the valve seats and I've found some valves that we'll be able to grind so I can get it all back together soon. I've also got some RFPs in with some valve manufacturers to see if anyone would be interested in reproducing these oddball valves & shims. Pretty happy to have options now.

[@karlvanboxel561]

@@KensWorldRestorations did u check Abuso think they may do em

[@karlvanboxel561]

@@KensWorldRestorations there’s a place called shims Australia that do the shims good price too

[@KensWorldRestorations]

@@karlvanboxel561 Thanks for that...I just found some here in Calgary as well as a supplier in the US. Cheers!

[@KensWorldRestorations]

@ they do. Also found a local place. I got lucky.

[@buster9538]

This is the video I was waiting for, I made myself some coffee and now 27 minutes of pleasure await me

[@KensWorldRestorations]

I love reading comments like this! Thanks so much. As I never really consider myself an expert, I don't ever want to label my vides as "how to" videos. I just want to share the experience and if someone else benefits, I'm happy. Take care.

[@Fireballspc]

Hi Kens Great job on disassembling and assessing the measurements and conditions of the internal moving parts. I can only imagine the technology involved in developing all of this for that time. Very good.

[@KensWorldRestorations]

The Yamaha engineers were cutting edge at the time. No doubt there is so much to consider. I can't wait to get all the engine parts serviced and repaired so I can get it all back together.

[@ChrisSofos]

Ken, once more, you created excellence!!! I loved the Wiseco addition in this engine! I'm looking forward to hear it roar! Keep up the good work my friend!

[@KensWorldRestorations]

Me too Chris!! Like I mentioned in the video, I was hoping to keep it stock concourse restoration but I think having it as a daily rider would be kind of cool. I have a few other "minor" mods that I'll be doing as well.

[@uhtred7860]

@@ChrisSofos Those Wiseco pistons are almost too good to be hidden away inside the engine 😆 they are truly things of beauty.😀

[@KensWorldRestorations]

@@uhtred7860 I'll take lots of photos of them!! Hahahaha!

[@yarekk]

Fingers crossed that you find new valves

[@KensWorldRestorations]

Thanks - I found a head in Germany complete with valves that looks ok. I might have to collect a bunch of them to get ones that are ok to grind and resurface. If not, another option is custom made valves - there's a few race shops out there that will do that. Stainless steel would be nice.

[@karlvanboxel561]

Abuso might do new valves they definately do ti retainers. The small ends on these have a tendency to elongate full synthetic helps

[@KensWorldRestorations]

@@karlvanboxel561 Thanks so much for the info. I checked with them yesterday and apparently I'm not the first to request it. Paulo was pretty clear that they don't make them and I'm not so sure he'd be interested unless there was a large order placed. Still not out of the question - there's a lot more interest in these bikes lately.

[@AshRowland]

This video is going to be the most important thing on KZbin for me in a few months time when my engine inevitably let's go 😂 well done mate, fantastic video, I can't wait until the bike is finished 👍👍👍

[@KensWorldRestorations]

Love, love, love the comment Ash!! I had so much of it done over the last couple months. I wanted to add in a bit just for you but I'll save it for the next video. After dropping all the stuff off at the machine shop, I was happy to know that the guy was a veteran and expert of the old FZ750/FZR series.

[@theodavies8754]

I had one in 1988. Clutch was grabby on launch. Brake calipers didn't make it through one winter. Gearbox wasn't as sweet as the GSXR750j. FJ1200 is oil cooled so one less thing to deal with. The FZR1000 took some effort to hustle but they are still seriously rapid and need to be treated with some respect. Good luck with your channel.

[@KensWorldRestorations]

I loved my FJ1100. Had the RZ500 too so I was hoping this would be something in between. I've got an EBC upgrade kit for the clutch so hopefully that will help. It'll be taken for regular rides when it's done but no hard days.

[@theodavies8754]

@KensWorldRestorations It should be about that. Tyre technology went to radial for 17" wheels which made the biggest difference in Tyre performance. I got through metzler comp k rear every 1000 miles which was the deal breaker after a few k miles.

[@robertmason8341]

I build Suzuki and some Kawasaki liter plus stuff mainly and found it really odd how Yamaha did the cam journals and bucket bores in an entirely separate casting to the head. So different from everything I’m used to from the z1/kz 900-1000 to gs1000-1150, to gsxr 750/1100 oil cooled to hayabusa and gsxr1000 everything is very similarly constructed. First thing I noticed when watching your video was the super long valve stem above the retainer/keeper area, suppose that extra length is necessary for the extra height of the separate cast section for the buckets. I’m thinking about why they designed it like that and if there are any benefits to having the two separate pieces! I suppose one is that if you had a cam journal problem and it wiped out bearing journals you should be able to replace just that section if it’s not a piece that is machined in place to a particular head. Without having ever worked on that engine and not having one in front of me I don’t really know if that’s the case or not, but in theory it seems plausible! When the head and bucket bores are all contained in the same casting as it’s traditionally done, any damage to the caps bearing journals or the head’s journals requires a new head unless you have relatively specialized equipment to skim the caps and then line bore the journal/tunnel back to size. Something so rare I only have heard of a few shops across the us even being capable of doing and only cost effective for the most rare head that replacements are unavailable or in the case of highly modified racing heads that would cost thousandths to duplicate!

[@KensWorldRestorations]

Hi Robert...thanks for the great comment. I love when people take the time to watch and comment. I think Yamaha wanted to get the bike to market for 87 because of a long list of new designs they wanted to test. The frame was one. That aluminum delta box was straight out of the GP world for street use along with a host of other bits. The engine was still in its infancy and there were a lot of strain at the time to streamline a lot of the manufacturing processes. Until the EXUP design, which is what you still see in todays designs, the cam followers, lifters, shims and springs were all unique to that first generation. Sadly, Yamaha has abandoned many of the Gen 1 parts (87-88) and finding things like valves and shims are nearly impossible. There is no support from Yamaha and there is very little left in the NOS/OEM world either. All we have left is used and "make as you go". I have no idea why the head was designed this way - probably because of left over parts from the FZ750 until they got the 89's rolling off the assembly line. I'm pretty lucky to have found a shop that can do all the machining I need as well as having a lot of experience (and some good used parts) for this bike.

[@uhtred7860]

Not line boring the cam caps in place on the head, was the main thing that caused the cam/valve gear problem on the Honda VF750 engines.

[@KensWorldRestorations]

That's exactly what my machinist said!!

[@KensWorldRestorations]

I'll take you up on that offer for the intake valves...just emailed you. Thanks so much.

[@jh-tech5546]

Hi Ken, another great video. You are definitely working like a pro! Sad the cylinder walls are damaged but look at the solution, what a nice set of pistons. Did you asked your machine shop if they can grind the valves and cut the seats? Good job!

[@KensWorldRestorations]

Thanks!! Yes, they can grind the valve seats and that's what they'll be doing. The exhaust valves are fine but the intake valves are cupped and he was fearing that if he grinds the faces flat to spec, they may be too small in diameter after the grinding. I ordered a whole head with valves from eBay but the order was cancelled so I'm still looking for intake valves.