D.I.Y Project Yamaha FZR 400

[enigmatool]

best of luck bhatti saab, kis cheez ko pakar baithay hain janab??waisay once my frnd owns this piece of crap, bike aur uski pocket dono ka bera garak kar diya tha mechanic nay.

[darim]

GOOD WORK , but whats now yaar

[Hasnain3958]

nice job

[Umar_Sargodhian]

Well the thread got kick start again,,,,hope same for the bike.........imran any new updates......

[imranbhatti]

@umar

I have re aligned the parts this weekend hope fully will resume work within this month.

Since there is some blow in exhaust( Engine is burning oil ) so the engine require some Cylinder/ Head work. on the other i hand got clue that some one is selling an FZR 400 engine so i m on it & may purchase the engine if its head cylinder was in good condition & i got fair deal.

[waseem88]

boys ici model ki bike in blue colour yahan faisalabad mein b ha,in v good condition

[imranbhatti]

SO back again to my project after a very very long break. Though have done many things like placing several missing bolts servicing of cooling system, repairing of exhaust headers & replacement/fixing of leaking gasket but cudnt update it on forum since i lost my cell phone in which details of these activities were captured.

Now coming to the recent activities,

New rear fender being placed


Fender's bolts after having bath in WD 40


Fitting complete



Battery box removal

[imranbhatti]

Some of the worn rubber gromets of battery box



New gromets installed on all required places


washers with spacers bush also installed

[imranbhatti]

New battery ready to be installed the stock one is 12N9-4B but that was not available in market so i buy 12N9-3B which has breather valve on opposite side so i have to manage the fitting of drain pipe

Battery placement in progress

Now cleaning of Rear brake fluid reservoir

[imranbhatti]

Left caliper of front brake was missing & i bought it year back

The right one was wid bike but i found that it jammed so bought the right caliper aswell

Old front disck brake pads

[imranbhatti]

Break Pads after having new leather

Pads fitted back in to break Calibers

[imranbhatti]

Front break Master cylinder was also leak so instead of replacing its seals etc i bought a good replacement form junk,

Servicing in progress

[imranbhatti]

Inspection of the piston kit & its seals for any wear n tear

Luckyly all the parts are in perfect condition so put it back after servicing

at next step found another doubt full part the pipe between the Master cylinder & break distributer was also worn out & to about leak

[imranbhatti]

The new pipe installed

The break pipe couplers which connects both front break calipers to single master cylinder.

Final connection of cali[ers to the coupler

Right side break caliper installed

[imranbhatti]

Left break caliber being installed

Break fluid filling

Break air bleeding in progress

Now its time drain the old lubricant

[imranbhatti]

Oil changed. Have put Havoline 20W-50

Front grill being put back

Instrumantation panel installed after cleaning & replacing bulbs etc

And the bike is start againafter 1 & half year

Lights & other accessories being fitted back before 1st test ride after replacing carburators & other parts.

[imranbhatti]

Tail light installed

Bought new indicators cover They are almost same as used in Yamaha Junoon

Tail light & rear indicators fitting complete

[star2]

great going bhatti Sb, lets finish this in this life................lol.

[VCheng]

This is a work-in-progress and I look forward to the end result, which should be great.

[waseem88]

MASHALLAH bohat zaberdast work hai...keep it up...