1986 Fazer FZX700 project

Good afternoon,

I was trying to deal with the brake and clutch master cylinders and I guess I wasn't that successful since I messed the seized screws on both cylinders.

I am here again to look for an advise from the experts. Should I look for a replacement master cylinders for both or is there a way to work on these to make them usable again.

If I go with replacements should I look for FZX specific cylinders or are there compatible cylinders I can look for?

Be safe and stay healthy!

 

I would go to a highly recommended machine shop and have drill and retap if needed

 

I will ask around and hopefully I will find someone that will be able to do it.

Do you know a place that will be able to do this work? I might arrange the shipping and pay them for the work if they'll be able to do it.

 

Good evening all,

I dealt with the master clutch and brake cylinders today and both are seized and I can't retrieve the piston out of the cylinder.

I used PB for the last few days to no avail.

Considering the messed screws for the cap of the reservoir and the bad condition of the master cylinders will it be better to look for a replacement or should I try to find a shop that can rebuilt these?

Which master cylinders out there, for the brake and the clutch, are compatible with the FZX700? I couldn't find any FZX700/750 in decent condition.

After a few days of PB on the calipers screws I was finally able to turn them all and I got all three calipers off the bike. I am about to take it all apart and my question is should I replace the o-rings or check the current ones and maybe reuse them?

I wish I could soak all the bike in PB Blaster and let it soak for a week...everything is seized so hard on it that I wonder if it's the rust/corrosion or that someone fastened them all too hard...this was supposed to be a project and it turned to be a challenge ;-)

The good news are that after a couple of weeks of PB and Marvel Mystery Oil treatment I was able to turn the engine and although the carbs are still off the bike I used some starting fluid and was able to get some life cranking out of it.

Thank you, be safe and stay healthy!

 

If everything is that rusted, corroded, set up and difficult to get apart the brake o-rings are going to be not re-useable. I would not be surprised if the brake pistons were very pitted and also not to be used again. If just dirty I have chucked the pistons in a lathe and polished them with scotch brite pads. But pitted means they are done.
John

 

Thanks John for the guidance.

I will expect the worst but hope for the best this is the state of mind I developed with this bike

What are my options of getting new/used master cylinder for the brake and the clutch? Are there any other Yamaha models that have compatible master cylinders that I can use?

Apart from being a challenge this is also becoming an expense I didn't expect but I have two other motorcycles to ride so I might slow down with this one and just take my time and do it little by little.

Thanks again, be safe and stay healthy!

 

For the clutch I have little advice to offer as I have not done anything on that side. I have used an ebay special R1 front brake master on my Seca 750 with good result. Chacal might have clutch masters available, new or used, or at least advice on same. PM him from the XJforever logo in the upper right of this page.
John

 

Good evening,

I started rebuilding the brakes calipers, front and rear, and I need to order a caliper joint seal o-ring, the seal between the two caliper parts, but I can't find the part in the service manual nor on the factory parts list.

I am sure I am missing something so here I am asking the experts...

Thank you, be safe, stay healthy and have a great weekend!

 

I am still unable to find the part description or the part number for this o-ring seal.
This is the o-ring seal that comes between the two calipers parts and I am unable to find it on the service manual.
Thanks, be safe and stay healthy!

 

XJ4ever will have them.

 

Good afternoon all,

I am working on the fuel tank and I found out that it's kind of a strainer basket with too many to count pinholes spread all over the tank.

My question is does anyone have a recommendation for a tank sealer or maybe another method to treat the tank for these leaks?

I might look for a replacement tank out there but for now I would like to treat this tank and use it.

Thank you, be safe and stay healthy!

 

Avi,

I've had very good luck using the Caswell on two tanks.
My spare Fazer tank has pinholes as well, and you reminded me, I should do that one too.

Here's the link to check it out:
https://www.caswellplating.com/epoxy-gas-tank-sealer/battleship-grey-motorcycle-gas-tank-sealer.html
(They advise to tape over the holes and it'll seal them up nice).


Tony

 

if its on the bottom I would try a 2 ply repair with fiberglass.

 

Thank you @xHondaHack and @Simmy

I looked at the Por-15 fuel tank sealer but since the Caswell is 3 x the $$$ I would like to believe it's also a superior product.

I looked also at soldering the holes but there are too many and I am afraid that it will be a never ending story with new holes popping up so sealing is a better solution.

Thanks again, be safe and stay healthy!

 

I have used both the Caswell and POR-15 kits and found the key to either is meticulous prep of the tank. Years ago I used the Caswell with not so good prep. It lasted for a long time but eventually pealed off the interior of the tank in small sheets. Better prep then and applied the POR-15 with excellent results. The tank did not have any holes or leaks, this was just preventative as I had had a tank on another bike fail due to rust through. 10 plus years later all is well. I have nothing bad to say about the Caswell, the failure of it is all on me.
John

 

Thank you for the info @Fuller56

I do see that there are many options out there for fuel tank coating/sealing and I guess you can never know which one is the best or will work the best on ones tank.

I just saw another one called Red-Kote and it has some good reviews as well.

I will try to read some more and try to pick one for my tank.

Decisions decisions...

Thanks again, be safe and stay healthy!

 

You are very welcome. I used Red Kote 1 time and it did not seal the rust holes. I had a different tank cleaned at a radiator shop and they applied Red Kote and soldered a hole and it was fine. I prefer POR-15.
John

 

@Fuller56 Thanks for the replies and the info.

I am debating now between the Por-15 kit and the Caswell

 

And now I have a 1986 Fazer 700!

 

That's a NICE looking tank!

 

I keep looking for them within a two or three hr drive. Never seem to be lucky enough to get my hands on one. Nice looking bike.

 

Tomah isn't far from Minneapolis, MN and I'm looking to sell it now that I've got it running and polished. It's a little on the small side for me but it is fun! I have a new (used) starter on order as this one makes some noise.

 

I saw a black one in your area for $1800.00 for sale, could not find your add. Good luck on the sale. She will sell, the sport version of the XJ700X imho.

 

I haven't posted it on Facebook Marketplace or Craigslist yet, waiting to get the title back from the state first (and hoping to get the starter noise fixed first as well).

 

I see, I am sure you didn't like the $164 for a title now days in WI. I guess they have to pay for the E pubs web site for all the WI DMV needs. I should not jab them too bad, they are fast with the epubs and they get titles out quick. imho

 

MN has you fill out a form online now and then a rep will follow up with an email requesting more info, then he doesn't get back to you for awhile and that's where I'm at right now. I currently have an in-person appointment in mid-October just in case.

 

Wow, well misery loves company sorry to say. I hope it goes well for you and that you get the paperwork to make her your baby.