FZ600 resto-rescue?

Going to test the stock brakes again tonight after I do some cleanup, however I think I have a plan for what I want in terms of from brakes eventually. I plan to do braided lines, with r6/r1/various other model calipers. My understanding is that the fzr caliper bolt pattern is different than the fz pattern, but shares a pattern with a bunch of more modern 4 piston monoblock axial mount calipers, like what came on bikes like the r6 and r1. Going to calipers from an fzr would require essentially the same amount of fab work as it would to go to r6 brakes, but I’d be getting better more modern, and cheaper to rebuild, calipers. There will likely be some spacing issues, so I would need to account for that in the mounting bracket, but I think the disk thickness should match closely enough, though I need to measure my disk when I get home. Hopefully I can make the stocks work for now for test ride purposes, but I do really want to go the modern route at some point


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Going to test the stock brakes again tonight after I do some cleanup, however I think I have a plan for what I want in terms of from brakes eventually. I plan to do braided lines, with r6/r1/various other model calipers. My understanding is that the fzr caliper bolt pattern is different than the fz pattern, but shares a pattern with a bunch of more modern 4 piston monoblock axial mount calipers, like what came on bikes like the r6 and r1. Going to calipers from an fzr would require essentially the same amount of fab work as it would to go to r6 brakes, but I’d be getting better more modern, and cheaper to rebuild, calipers. There will likely be some spacing issues, so I would need to account for that in the mounting bracket, but I think the disk thickness should match closely enough, though I need to measure my disk when I get home. Hopefully I can make the stocks work for now for test ride purposes, but I do really want to go the modern route at some point


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I think a better route would be to put a whole r6 front end on for better/bigger forks, better brakes and a 17" front wheel. I have heard that the last year for conventional r6 forks is 2005 or 2006. It will brobably be cose to a bolt on with bearing changes.
 
I’m fully in agreement with that statement, as I really do want to go to a 17” front wheel as well, and modern forks would be very nice, but I’m playing the long game a bit here. If the bike pans out to be a strong runner and solid platform, it will most likely see something like an r6 front end. However, financially I really can’t be dropping that kind of money on something I’m not sure about. But yes, someday….


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I've got a set of USD Kawasaki ZX6r forks you can have, complete with brakes and a front wheel, but no triple clamps.
 
Sounds as though the Gods of Motorcycling are continuing to smile upon you, @benroloff, there ought to be some triples on eBay... you'd be all set.
 
Sounds as though the Gods of Motorcycling are continuing to smile upon you, @benroloff, there ought to be some triples on eBay... you'd be all set.

Guess so. Looks like next time I’m in your neck of the woods Ken I’ll have to swing by again. It’s like having a fairy godparent but for motorcycles
 
No problem, I'll set them aside or maybe we will make a trip up to Duluth to see the sights and I"ll let you buy me a beer.
 
No problem, I'll set them aside or maybe we will make a trip up to Duluth to see the sights and I"ll let you buy me a beer.

You’ve got a deal. If you don’t end up this way at some point I’ll have to bring the bike back down so you can see the old stag.

Did you find a bearing set to make the zx forks bolt up to the fz stem? Or were you thinking stem bolt swap?


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It looks like the FZ600 uses a 25x48x15 top bearing and a 30x48x15 lower. The ZX6R has a 30mm OD stem, top and bottom, so 2 lower FZ bearings should allow the ZX6R triple to bolt into the FZ frame. The only thing to take into consideration is the length of the stem. I have covered that on other bikes by using spacers, shortening or lengthening the stem by cutting and welding with a plug. The other thing that needs to be considered is making steering stops work.
 
I thought I had read that zx bearings were 35mm ID. Maybe I’m wrong though. I can’t seem to find any 35x48 bearings if that does turn out to be the case, but I may be able to swap stems though. No matter really though, most of the stuff left on this is pretty long term as it’s all rather expensive, and with classes starting again soon I won’t be putting much money into it over the next year or two unfortunately. I will probably try to get the brakes functional so that I can do practice riding somewhere though, and that should hold me over for a while. I tried them the other day and it ended up with me on my ass and a broken clutch lever in front of the house. Somehow on two identical lever pulls, back to back, the first one had a tough time slowing me down, and the second locked the front brakes haha. No harm no foul though as it was a slow speed test run to test the system, and a very good learning experience. The most damage was to my ego…


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It looks like I will be coming to Superior on Sept 9th for my grandson's high school football game. We are going to try and make as many of his games as we can since he is a senior, this year. If that happens, I'll bring the front end along.
 
I should be in town that weekend, but if not no worries at all, we can find a time to connect at some point!


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So it turns out all I needed to fix the front brakes on my Japanese sport bike was a set of English bike brakes… yea that makes sense. I did some digging and found out that Yamaha used 83mm bolt spacing on these bikes for the calipers, which was kind of the end of the line for that spacing, meaning the stock calipers were about the best you could get, apart from some hard to find ones that came on some fzr400’s. Anywho, in the late 90’s and early 2000’s, triumph used some brakes produced by nissin and rebranded that utilized 83mm bolt spacing. I found a set with a master on eBay off of a tt600, and they bolted right up, offset and all. The bike now stops very nicely, though I think I’m still fighting some air in the system somewhere. One of the calipers seems to be dragging a bit too, so a rebuild is probably on the agenda, and I figure with rebuilt calipers and a vacuum bleed, I’ll be in a good spot. I haven’t decided if I want to remove the triumph logo or not, it does look kind of dumb imo, but I also find it quite amusing haha.
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So for any other fz or fzr400 genesis guys out there, as well as I think pretty much all of the bikes in this era and size class from Yamaha, if you’re looking for a set of these, you want something from late 90’s to early-mid 2000’s triumphs, models 955i, tt600, and maybe a couple others. There’s info on some other forums out there as well, but I think as long as they look like these, they should work.
Now, I do still want to do the front end swap on this bike, but this at least makes it rideable, and now I can save this front end for another project down the road and have a set of working brakes good to go. I was able to ride it with a but more vigor now that the brakes work, and after tightening everything down and doing bolt checks, I can confidently say- it kind of rides like shit. I mean, this is my first sport bike experience, and I do understand that it isn’t gonna be very good on crappy Minnesota city streets, and it’s not the most comfortable bike etc, but it feels rather unstable to me, and doesn’t track very well going down the road. I think some of this can be chalked up to the 10 year old bald tires, and I’m thinking stuff like steering stem bearings and stuff is the rest of it, but if any of you gurus out there think I might be just an idiot and I’m missing something blatant, please impart your wisdom.
Anyway, I’m pretty happy. This bike will probably be a side project for me for most of college until I can afford to do it all the right way , but right now I have a running and riding 80’s sport bike in my garage, and that’s just too damn cool to me.
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The stock rear suspension on the FZ was very harsh on the rear from new. I think it is a combination of too soft of a spring, too much compression damping and not enough rebound, all built into a cheap steel non-adjustable shock. I have replaced a coople of them with the shock off a CBR900RR as it is the right length and the damping is adjustable. The spring rate is also pretty good, as is. It is a pretty tight ride, but has worked well for me on the track. The only mod needed is to grind some clearance on the link that goes between the bottom of the shock and the swingarm so it doesn't bind on the shock body when the swingarm compresses the shock.

I will be coming to Superior this Friday for my grandson's football game and can bring the front end. I expect we will be there in the middle of the afternoon and then a 7 o'clock game. If you want them, I also have an FZR1000 swingarm and YZF R6 rear wheel you can have, that you might be able to make fit on this bike or some future project.
I'll text you when I have more firm Friday plans, but we will probably have a late afternoon dinner in Duluth.
 
My moto-genie stopped by on his way through town a couple weeks ago and left me some treats, thanks again Ken!

Got some inverted kawi forks, we thought off of a zx6r but I believe they came off of a zx7, along with the accompanying wheel. This should be a really nice front end setup, and I think the bearing swap will be much easier that using a zx6r actually. I also acquired a fzr1000 swingarm(which I have no idea what to use for, though I’ll keep it anyway cause you never know), and an r6 wheel, which I would love to fit to this bike but I’m not sure it’s even fit inside the swingarm, so maybe the fzr1000 swingarm and r6 wheel someday then would be a cool project. Cool stuff!
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I’ve been fighting the carb boots on this bike since I got it. They aren’t too hard or brittle, but they are cracked up pretty good. I tried some silicon sealant for a temp fix, but it failed quickly. I did a bunch of part number searching, and found that part numbers for seca 550 boots are almost identical, and about $100 cheaper. I ordered a set and had to clearance the mounting holes just a tiny bit, and was able to make them fit just fine. Maybe not perfect, but dang close, and the bike now runs better than ever. I’m going to keep chipping away at the small stuff this winter, but I’ll likely be saying goodbye to this one in the spring or summer of next year, so if anyone is interested, let me know, I’d love to see it go to someone here if it has to go!

Oh and here’s a shot of the old boots, yuck lol
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