my 4FL...

[41juergen]

So I have started a new project, I bought a used 4FL. I got that cheap, of course it needs a new heart (engine is broken), some renovation of her clothes (the seat is a racing one without cutout for the taillight, the fairing V-piece is missing, etc.) and a new makeup (no paint job at all).

I will take her apart, get the frame and swing arm painted and will put everything together. To get the TÜV approval I will use the engine of an other 4FL I have (will be sold after that) and then start to build the engine taking a 3XV barrel and a new pipe.
I have a R model stock fork which I will take and will convert the electric system with a available 3XV loom (no E-starter any more...)

[41juergen]

I took the bike apart on the weekend and found one strange thing with the ignition key mounting... There are no bolts like on my 3XV or RZ, only this kind of clamps.



So has someone a good idea how I can remove them or cut that back to take the things apart?

[Louis]

Braking bolds   they are common in the car industry for parts witch are not mend to remove easily

The Top was probably imbus or torx, you tighten it more and more until the head brakes off.
You can try to tap a bid on top so it is nice and flat start drilling with a 1,5 or 2mm drill and go bigger as it goes.
Until you drill the remaining head off and you can remove the key lock

[41juergen]

Thank's Louis will try...

[tzr-v4]

You can also use an arc welder.
The heat will destroy the loctite if any and the metal dilation steel vs alloy will make the unbolting more easy.
If the can stick the welding rod on the bolt then you could unscrew it.

I'll not be as it was for me.

[41juergen]

That's an good idea Oliver, thank's!

[No.406]

What is a 4FL?

Love the paint job - what we call the "clown car" look:

[41juergen]

The 4FL is the "Japanese" TZR125 here in Germany, it has some parts shared with the 3XV. The Swiss version is a 4HX I believe...
VW sold a POLO Harlekin longer time ago... 

[41juergen]

Just a question: is it correct that the 4FL engine don't has an oil pump cover installed? In the repair / spare parts manuals it can be seen that the DT's or Sachs engines have one...

[Martin77]

This is correct, 4FL's do not have an oil pump cover as they use a different type of pump that does not fit under the older TDR/sachs cover.

I wanted a cover for ours, so modified an earlier one.

I guess yamaha were lazy and decided not to bother making a new design cover for the 4FL!

[41juergen]

Thank's Martin for the info. Would you share a pic of the one you made, I like that idea... Or will may be the one from a 4DL fit?

[Martin77]

I'll take a decent picture for you tomorrow 

[Martin77]

Pics of oil pump.. you can see where the plastic has been cut away and reshaped with body filler to fit over the large roil pump. The cable area has a bit of curved steel, held in with filler and glue. 

[41juergen]

Perfect, thank's a lot Martin. I will try to copy that idea (if you allow... )
cheers
Juergen

[Martin77]

It's a fiddly job, but satisfying once you've done it..