I last weekend I started by pulling the YZF600's engine and got the head off before it got too late. At that point, everything looked pretty good.

This weekend, I split the cases and found:
a.) metal shavings in the oil galleys, inside the oil jets, and under a couple of the bearing shells.

b.) pitting and scratching of the bearings

c.) the wrong size bearings installed (!!!) just about everywhere. It seems that some other monkey has been inside this engine at some point and tried to install thicker bearings but misunderstood the color codes and went with thinner (bigger clearance) bearings instead which probably caused these problems. I'm dropping the crank off at a machine shop that works on motorcycles tomorrow morning to see if the journals can be polished. I don't feel any grooves.

d.) two of 6th gear's engagement dogs were rounded off with significant material loss. The shift fork was significantly thinner than the new part and the shift drum had some rough marks where 2nd gear engages. The shift selector shaft was cracked and bent.

Hopefully the crank will be usable. If so, new bearings will be ordered and I can start assembling.

 

Wow. Quite an undertaking!

Good luck man.

 

Its a seller's market!

 

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by ScareyH22A &raquo;</TD></TR><TR><TD CLASS="quote">Its a seller's market! </TD></TR></TABLE>

Hahahaha...

I have supreme confidence in duy.

 

I dropped the crank off at a place called Marine Crankshaft in Santa Ana today. The website says that they specialize in motorcycle cranks and they're not kidding. I pulled the crank out of the bag and the guy says, "Is this from an old Yamaha FZR?" Close enough!

 

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by Jasper_db1 &raquo;</TD></TR><TR><TD CLASS="quote">I dropped the crank off at a place called Marine Crankshaft in Santa Ana today. The website says that they specialize in motorcycle cranks and they're not kidding. I pulled the crank out of the bag and the guy says, "Is this from an old Yamaha FZR?" Close enough!</TD></TR></TABLE>

Nice, they must really know their stuff! Hard to find shops like that these days.

 

Since I'm waiting for some parts to arrive and some to come back from the machine shop, I started installing the YZF750 Sharkskinz bodywork I picked up over a year ago. The YZF750 is a couple of inches wider than the YZF600 so I'm considering cutting the fairings right down the middle and fiberglassing them up at the correct width.

Here are some teaser pictures:
Say good bye to the beatup OEM fairings, Donkey!


Mounted:


Another angle:


I had to cut the OEM fairing bracket in order to mount the 1-piece upper at the 5 and 7 o'clock positions. I'll have to relocate the horn but that's no big deal. As for the headlights, I ordered a pair of Hella 90mm H7 projectors that run at 65W. I was so impressed with the 90mm HID module I installed on the RC51 that I had to upgrade the YZF's lighting.

 

Is this the same bike you blew the 2nd gear out of a few months ago? I reember something being posted about that...

 

Tis indeed... design defect I am sure.

HEY!... you promised me you'd be 69 not 89

 

Yes, this is the bike. Here's what caused the 2nd gear slippage:

Worn engagement dogs on 6th gear which interfaces with 2nd.

Here it is again compared to the new part on the left:


Worn shift forks:


Broken shift selector

 

Judging by the size of those acorns, you must have giant squirrel population. Get spike back to work doing rodent control patrols

 

He'd much rather sleep than kill anything. Lazybutt is leaning on my leg as I type (@ home 2day)

 

I installed the windscreen and made new mounts for the upper which I'm not totally happy with. I think I'm going to redesign them and use some DZUS 1/4 turn fasteners.

I also mounted the solo tail section and put the tank back on for show


Next I need to make new headlight mounts and mount the tail lights.

 

Looks a bajillion bucks better!

 

about how much he has in it now

 

YZF600r content -

 

I seem to see them like that all the time

 

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by MSchu &raquo;</TD></TR><TR><TD CLASS="quote">I seem to see them like that all the time </TD></TR></TABLE>

Well, it ended up being a bad battery connection.

Reliable other then that.

 

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by Jasper_db1 &raquo;</TD></TR><TR><TD CLASS="quote">
</TD></TR></TABLE>

 

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by Ajax &raquo;</TD></TR><TR><TD CLASS="quote"> Reliable other then that.</TD></TR></TABLE>

My engine has been stone reliable (same technology I'm sure). The transmission is another gig