Daniel

[Daniel]

Thought you might enjoy my mini BBQ. An on going project I finally managed to get done since I got stuck on the buggy.

[Daniel]

Some pictures of my progress and problems.

1. Getting the buggy off the stands with no one at home
2. Angling the engine without an engine hoist
3. All the electronic components I have
4. Dash
5. The clutch
6. My attempt at a stripped back wiring diagram

[Daniel]

After 2 months of work I thought I was about a week from firing the engine, but I’ve hit a number of problems that I could use some help with.

1. I think the chap who sold me the buggy may have ‘misplaced’ the CDI unit. I also can’t locate any of the following:

• Clutch switch
• Fuel and . . . switches (locate on the left side of the wiring diagram just below the AC generator, they go into the main relay and the high beam blub ) My diagram’s missing hal the name
• CDI unit
• Sender
• Thermo switch
• Temperature gauge
• Oil light
• Thermo unit

Which are necessary for the engine to run and which can be by-passed?

2. Does the thermostat housing and cap mean there’s no need for an expansion tank? And would any thermostat & cap that fits work or is it FZ750 specific?

3. On my diagram I have decided to earth each component individually rather than run them all back to the negative leg on the battery will this be OK?

4. I assume that like a car ignition a motorbike key turns 2 clicks before pushing to a third? If so will I be able to wire it so that the first 2 clicks can be operated by one ON/OFF toggle and the 3rd by a push to make missile switch (from an actual fighter jet!)

5. From looking at various pictures online I believe the hydraulic clutch pipework enters the engine just in front of the spur gear, all I have is a rod that slides in an out of the gearbox. I have a spare brake master cylinder will that work, and how to I plumb it in?

6. The wiring diagram I have is for a single pick-up model, my engine has two is the wiring drastically different as I can’t find a diagram anywhere online for my model.

[Daniel]

I was told the engine is a strong runner, but then I was also told is was from a 91 FZR750! I’m a student with lots of spare time and little spare money so I’ll do my best to get this engine to work this summer, I have a friend whose’s a mechanic coming over on Sunday so I’ll get him to have a look at it..

As far as I know I have everything I need other than a sprocket, tank, air filters and the hoses / cables. I believe the loom is complete but it is a bit of a mess!

The buggy is at home in Suffolk, but I’m studying the Sheffield so I’ll be back and forth between those two for the next couple of months.

[Daniel]

Thanks for your help Graham. I shall pick up a Clymer manual and get started.

First thing I think it to brace the engine properly, it’s currently only held on by the 2 mounts at the back of the engine and one of those is just a coach bolt!

[Daniel]

The plate on the engine reads *1FN-000471* if that helps.

[Daniel]

All I really needed to know what it was! I was told it was from a 1991 FZR750 but the chaps on the FZR forums said it looked more like a FZ750 so I came here.

I need to get my hands on a manual for the bike so I can piece the wiring loom back together, but the only manual I can find is for bikes built between 1985 – 1987. My knowledge of bike engines isn’t very good, do you think I’ll be able to use the diagrams in these manuals, or are there ones for the 1991 model?

Thanks for your help

Dan

http://www.ebay.co.uk/itm/CLYMER-MANUAL-YAMAHA-FZ700-FZ750-FAZER-1985-1987-/200767361483?pt=UK_CarParts_Vehicles_Manuals_Litterature_ET&hash=item2ebeaad1cb#ht_500wt_1180

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