Hey guys!
So finally we have been able to progress some more with the 2000 Cafe Fazer Build!
After a few weeks of difficult circumstances, I got bored and decided to get on and replace the fork seals, in doing so i discovered the stanchion tubes were dented and were pitted. Before I got any further, I hit up the internet to see what options were available regarding fork swaps, progressive spring upgrades etc. I discovered the cheapest and most effective option was a Yamaha Thundercat fork swap, so I began to search. I came across a full front end from a 1998 Yamaha Thundercat on Gumtree (other sites are available! ;) ) He was based in Swansea and wanted £50 for a full front end, minus the wheel. A few phone calls later and it was ours to collect when we could! Friday appeared and we packed some snacks, some drink, some stuff to do, set the Satnav up on my phone and after running through a checklist (may only be Swansea from Exeter, but hey its the furthest we've been yet!), we ran upto Tesco, chucked some air in the tyres, filled the car with fuel and off we went! Luckily the roads were fairly quiet, however when we left Gordano Services after a pee stop and getting roped into an AA Breakdown cover scheme, the roads were suddenly FULL. After crossing the Severn Bridge, it only got worse. We averaged about 10mph on the M4 for nearly an hour. Eventually the traffic started to break up and we were well on our way again, we should have been there an hour earlier! We finally arrived and it was all ready to take. We also got given a load of other Thundercat parts from a previous project of his, this included a rear shock, gauges, a rear caliper it was endless! Emily couldn't resist a track tail fairing from a ZX6-R, she wanted to fix it up, spray it and sell it on, can't blame her! The trip home was uneventful, much shorter and quieter than the trip up. When we got home, I couldn't resist having a play and offering up the new forks. At first, I fitted them using the Fazer yokes as I was under the impression I needed to have the stem swapped from the Fazer Bottom Yoke over to the Thundercat Bottom Yoke. More than anything I needed to be able to wheel the bike around again! In they went, followed by the wheel, top yoke and the Thundercat Clip ons. After I switched all the controls from the old bars over to the clip ons, I fitted the calipers. The way the speedo drive sensor fitted, meant for the time being the wheel wasn't central. This meant that the left hand caliper fitted ok, but the right side was miles off of lining up with the brackets on the forks and fitting over the disc.
I had, had this niggly feeling that I needed to strip the engine down, and check it all thoroughly, replace all the gaskets and bearings etc. When I first checked the engine, I just took off all the side covers and did a very basic service and new oil, I was excited to get it in the frame and running! After I had finished with the forks, I decided to remove the engine and start from the beginning with it. I started by draining the oil and coolant then removed the battery, followed by the carbs, airbox and the rest of the ancillaries and disconnecting the wiring loom. I had a block of wood and a jack underneath the engine, ready, I removed the engine bolts and front mount and began to lift it out. Damn its awkward and heavy when you don't have the right equipment! I tried and tried, all different angles and just couldnt get it out of the frame. It was then, that I remembered that the right side rear engine mount has to be removed completely and it will only fit out the right side once done so. Then BINGO! It was out! And quite rapidly up on the work bench.
The following day, began to strip the engine down in accordance to the Haynes Manual. All the side covers came off, followed by the the camshaft cover and camshafts, cylinder head, cylinder block, oil cooler, oil sump, water pump. starter motor and starter clutch then onto the clutch! All was ok until I got to removing the main clutch nut, boss and basket. I could not get enough force onto the ratchet while attempting to stop the boss from rotating. I foolishly tried putting a screwdriver between two of the clutch spring lugs to make it easier to hold the boss still. SNAP... DAMN IT... I gave up and am waiting til payday to get a clutch holding tool, I also now need to add a new clutch boss or second hand clutch assembly to the list of parts needed! :(
I cleaned up the cylinder head and block, both of which are in good shape! And straight! I removed the crankcase bolts, triple checked there was nothing left and began to try splitting the crankcase halves. Not a hope in hell of getting those two apart. A quick call to the local Motorcycle Dealer and discovered they could split the halves for an hours labour at most! I'll leave it to them I think :P
The following day I examined the Thundercat Yoke and stem and compared it to the Fazer one, that was on the bike. I concluded it was worth my while just to whip the front wheel and forks back out and experiment with the Thundercat setup. Turns out it fits perfectly! Just need a new Thundercat Top Yoke and front wheel spindle, then we should be set for a complete front end swap!
I'll be back soon with more to report,
Max.
