A few weeks ago, a fellow reached out to me on Facebook (thank you Fred for steering him in my direction), asking if I would be willing to take on a project to bring this FJ back to running/ride-able condition.
After a couple discussions about what would be involved, and what it was, of course I agreed!
It turns out that Robert (the Gentleman who contacted me on Facebook) found the bike for his long-time friend JD, who was searching for a motorcycle to get into.
This particular FJ was tucked in a garage with a bunch of other motorcycles. After looking it over, and doing a little bit of research, JD purchased the bike.
I'd have to say, that he couldn't have purchased a better project-bike, although due to the circumstances involving how it was stored, there was obviously going to be some challenges.
Basically it was simply parked, full of fuel, and there it sat for around 20 years............. :nea:
One can only guess what 20-year old fuel smells like, but I can assure you it's not pleasant........ :bad:
What I drained out of the fuel bowls stunk up my whole garage! :shok:
Luckily, they had already taken the liberty of having the tank cleaned out before it was brought to me........ :yahoo:
There was no longer any fluid in the clutch system, and most moveable items were "stuck" in place........
Anyway, the FJ was dropped off at my house on October 30th.
(http://i859.photobucket.com/albums/ab154/firehawk068/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/857DD747-DA8E-4AFD-83B1-91A688E1F2FD_zps2xifob6d.jpg) (http://s859.photobucket.com/user/firehawk068/media/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/857DD747-DA8E-4AFD-83B1-91A688E1F2FD_zps2xifob6d.jpg.html)
(http://i859.photobucket.com/albums/ab154/firehawk068/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/12EAAA96-C172-4143-807A-86B98C57F435_zpshvenbdja.jpg) (http://s859.photobucket.com/user/firehawk068/media/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/12EAAA96-C172-4143-807A-86B98C57F435_zpshvenbdja.jpg.html)
(http://i859.photobucket.com/albums/ab154/firehawk068/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/8602B8C3-C27A-40AD-B9EE-14849827C015_zpseva2ity9.jpg) (http://s859.photobucket.com/user/firehawk068/media/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/8602B8C3-C27A-40AD-B9EE-14849827C015_zpseva2ity9.jpg.html)
(http://i859.photobucket.com/albums/ab154/firehawk068/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/F8B84D88-EFBF-4361-9AF0-766EB783D60D_zpscrlh4b9g.jpg) (http://s859.photobucket.com/user/firehawk068/media/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/F8B84D88-EFBF-4361-9AF0-766EB783D60D_zpscrlh4b9g.jpg.html)
This particular FJ was last registered for the road in 1994!
(http://i859.photobucket.com/albums/ab154/firehawk068/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/30F2B960-9A94-43BD-8EF9-6708222D70D7_zpsjnv4zr5x.jpg) (http://s859.photobucket.com/user/firehawk068/media/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/30F2B960-9A94-43BD-8EF9-6708222D70D7_zpsjnv4zr5x.jpg.html)
Obviously fork seals are needed.
(http://i859.photobucket.com/albums/ab154/firehawk068/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/A895DA90-8728-4719-978C-97B31FE2772B_zpswqmtwu7e.jpg) (http://s859.photobucket.com/user/firehawk068/media/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/A895DA90-8728-4719-978C-97B31FE2772B_zpswqmtwu7e.jpg.html)
20+ year old tires needed to be replaced.........
(http://i859.photobucket.com/albums/ab154/firehawk068/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/F768F316-A52E-4A82-9869-F924202DA9E0_zpsrj9y5dgg.jpg) (http://s859.photobucket.com/user/firehawk068/media/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/F768F316-A52E-4A82-9869-F924202DA9E0_zpsrj9y5dgg.jpg.html)
But the very best part of this project bike...............................It wasn't ridden much in the first 10-years it spent on the road!
(http://i859.photobucket.com/albums/ab154/firehawk068/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/B3F1DF8D-ACC1-4E03-B529-8B822ED35625_zpsbg6oapzn.jpg) (http://s859.photobucket.com/user/firehawk068/media/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/B3F1DF8D-ACC1-4E03-B529-8B822ED35625_zpsbg6oapzn.jpg.html)
More to come...................
That's how my 86 was. My friend said it was 10 years or so. But after a while we figured out it was 16 or17 years. It had a full tank when he parked it. There was an inch or so of nasty stuff left. I cleaned, and cleaned the tank. Then I proceeded to clean the carbs. Over and over and over. It would run great for a while. Then something would break loose. And plug a jet off come the carbs. finally. Only have to do it every once in a while. You should probably show them how to clean the carbs. Or convert it to fuel pump. So you can run a filter..
Mine Had 10,465 miles on it. Everything that had brake fluid. Was junk. So rather than rebuilding the forks and front brakes completely. I decided to take all the money I would spend rebuilding everything. And put it towards the inverted front end.
But that bike looks complete, and mint. Would be good to restore. Mine already had the supertrap exhaust. And air box out. Stuff like that. Looks like a great project.
Get the carbs overhauled, replace brake lines rebuild/replace brake slaves, seals, tires of course and you are have gem. Too much trouble? Sell it to me :biggrin: That's like NOS man. (just learned that acronym).
I'm gob smacked that that bike has just been sitting in someone's shed for a very
long time. How does this happen? Mine was also a barn find but after driving down his dirt road I can understand why it got put away. Any reason why your bike has been hidden away for so long?
Quote from: Davo231481 on November 23, 2016, 03:42:56 AM
I'm gob smacked that that bike has just been sitting in someone's shed for a very
long time. How does this happen? Mine was also a barn find but after driving down his dirt road I can understand why it got put away. Any reason why your bike has been hidden away for so long?
I'm unsure of the exact circumstances of why it was parked for so long. From what I'm told, it changed hands at least once during that time, but wasn't ridden.
The person that it was purchased from is a "Motorcycle Guy" that had a garage full of bikes.
My guess is that since it didn't run at the time, it was just relegated to a spot in the garage until the time came for someone to get to it? Turns out, that took 20+ years.......... :unknown:
Anyway, the bike isn't mine. I wish it was!
It's a project that I've been paid to do.
I was unable to work on this FJ for a few days after it was dropped off, due to me receiving a stomach-bug the very next day.
I was out sick for the next 3 days.......... :bad:
Since we were waiting a couple days for the initial order of parts from Randy anyways, it wasn't really an issue.
When the following Friday rolled around, I was feeling good enough to get out in the garage and spend some time on it.
The first thing I did was remove the back wheel, and strap the bike to the floor so that I could work on the front end.
Removed the front wheel also, and called Robert to come get the wheels so new tires could be fitted, and he could drop off the parts from Randy.
(http://i859.photobucket.com/albums/ab154/firehawk068/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/1AE9DD7B-C477-4944-AFA8-0706C78CD37D_zps36x5bsie.jpg) (http://s859.photobucket.com/user/firehawk068/media/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/1AE9DD7B-C477-4944-AFA8-0706C78CD37D_zps36x5bsie.jpg.html)
Next, I removed the forks for the obvious rebuild they needed.
(http://i859.photobucket.com/albums/ab154/firehawk068/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/619C7DF5-8B72-488D-935E-7DD6C24A3D00_zpsbvcqzwe0.jpg) (http://s859.photobucket.com/user/firehawk068/media/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/619C7DF5-8B72-488D-935E-7DD6C24A3D00_zpsbvcqzwe0.jpg.html)
(http://i859.photobucket.com/albums/ab154/firehawk068/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/8CB4A016-EEEA-40A3-8C7C-A4D9C0F57CDD_zpsburngnnd.jpg) (http://s859.photobucket.com/user/firehawk068/media/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/8CB4A016-EEEA-40A3-8C7C-A4D9C0F57CDD_zpsburngnnd.jpg.html)
Of all the FJs I have ever seen, I've never noticed a factory KYB sticker on any of the forks.
While cleaning these, I noticed this bike still had one on the back of the left side fork lower.
I took care while cleaning to make sure it stayed on there.
(http://i859.photobucket.com/albums/ab154/firehawk068/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/D3ED3467-273B-4D7D-B1E9-A1C368EB422D_zps8w0ti0id.jpg) (http://s859.photobucket.com/user/firehawk068/media/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/D3ED3467-273B-4D7D-B1E9-A1C368EB422D_zps8w0ti0id.jpg.html)
That evening, I pulled apart the forks for cleaning/inspection.
(http://i859.photobucket.com/albums/ab154/firehawk068/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/D795E3A7-FD73-4744-9395-71547764D18B_zpsnlxja2ws.jpg) (http://s859.photobucket.com/user/firehawk068/media/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/D795E3A7-FD73-4744-9395-71547764D18B_zpsnlxja2ws.jpg.html)
The bushings looked good. We didn't worry about replacing them. With only 8300 miles on the bike, I would hope they weren't worn yet.
(http://i859.photobucket.com/albums/ab154/firehawk068/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/CE3B43DF-3F3E-4BC7-98C5-BEB5341012B7_zpsbwxqdg0q.jpg) (http://s859.photobucket.com/user/firehawk068/media/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/CE3B43DF-3F3E-4BC7-98C5-BEB5341012B7_zpsbwxqdg0q.jpg.html)
There was a bit of dirt in the bottom, but all the parts looked perfect.
After a bunch of cleaning all the parts, I re-assembled them using a little fresh fluid and new seals.
Super shiny, and ready to go back on the bike!
(http://i859.photobucket.com/albums/ab154/firehawk068/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/263FFF5D-0590-46F7-92D9-932A4855A028_zpsbuochqgm.jpg) (http://s859.photobucket.com/user/firehawk068/media/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/263FFF5D-0590-46F7-92D9-932A4855A028_zpsbuochqgm.jpg.html)
The next day when Robert dropped off the wheels with new tires mounted, I showed him what the steering felt like with no load or forks mounted.
It wasn't good. :nea:
It was very tight, and felt rough near the center, so apart it came!
(http://i859.photobucket.com/albums/ab154/firehawk068/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/2C2859F4-31EF-45FA-813E-788EFF73EF48_zps7kgmy2ha.jpg) (http://s859.photobucket.com/user/firehawk068/media/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/2C2859F4-31EF-45FA-813E-788EFF73EF48_zps7kgmy2ha.jpg.html)
This is what the upper race looked like after cleaning it. (yes this is clean)
(http://i859.photobucket.com/albums/ab154/firehawk068/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/03416177-5D6C-4EF9-ADF6-C88F1461578A_zpsruuwdswo.jpg) (http://s859.photobucket.com/user/firehawk068/media/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/03416177-5D6C-4EF9-ADF6-C88F1461578A_zpsruuwdswo.jpg.html)
The lower bearing and race were fine, just the upper one was bad.
You wouldn't think that with only 8300 miles on the bike it would have an issue with the steering stem bearings? :scratch_one-s_head:
My guess is that someone early on in the life of this FJ tightened the steering stem nuts too tight for some unknown reason? :unknown:
Then it did sit for 20+ years like that.........
While I was waiting for Robert to return with a new upper bearing and race, I cleaned all the grime off the wheels and brake rotors.
They came out nice!
(http://i859.photobucket.com/albums/ab154/firehawk068/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/4B013412-095B-49B0-82D7-CF98BBB05488_zpsmiwoxbai.jpg) (http://s859.photobucket.com/user/firehawk068/media/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/4B013412-095B-49B0-82D7-CF98BBB05488_zpsmiwoxbai.jpg.html)
(http://i859.photobucket.com/albums/ab154/firehawk068/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/A08FC9AB-6DDB-4658-A754-3633F65B808A_zpsypxhrawl.jpg) (http://s859.photobucket.com/user/firehawk068/media/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/A08FC9AB-6DDB-4658-A754-3633F65B808A_zpsypxhrawl.jpg.html)
I then set about trying to remove the upper race from the frame.
I got my longest punch, and BFH.
After a number of good hard blows, I could tell that the race wasn't going to budge. :negative:
I very carefully cut a slot in the race with my Dremel, and after a very light tap with the punch and hammer it popped right out.
(http://i859.photobucket.com/albums/ab154/firehawk068/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/ED1EE874-B85A-46D7-B3BC-76F6B22D3151_zpsufyojpkm.jpg) (http://s859.photobucket.com/user/firehawk068/media/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/ED1EE874-B85A-46D7-B3BC-76F6B22D3151_zpsufyojpkm.jpg.html)
(http://i859.photobucket.com/albums/ab154/firehawk068/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/FFC61437-CD17-4848-A897-E3CC352F2102_zpsg0xuqayp.jpg) (http://s859.photobucket.com/user/firehawk068/media/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/FFC61437-CD17-4848-A897-E3CC352F2102_zpsg0xuqayp.jpg.html)
Wow what a project, looks great ! So you have to give this bike back when you are finished, what a keeper it would be
Tell the man that the engine is toast and offer him what he payed for it. :rofl:
Nice find Al. Those old tires were easily the worst I've seen, but the rest looks ready to roll
After receiving the new upper Stem Bearing, I used my driver set to install the new race neatly in place.
(http://i859.photobucket.com/albums/ab154/firehawk068/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/B5066447-3E14-4901-99E1-0833A6C7A205_zpsy0rgpaw7.jpg) (http://s859.photobucket.com/user/firehawk068/media/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/B5066447-3E14-4901-99E1-0833A6C7A205_zpsy0rgpaw7.jpg.html)
(http://i859.photobucket.com/albums/ab154/firehawk068/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/3FB451A9-2DB1-4249-897B-6F820772B6F9_zpsmvtu1g6n.jpg) (http://s859.photobucket.com/user/firehawk068/media/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/3FB451A9-2DB1-4249-897B-6F820772B6F9_zpsmvtu1g6n.jpg.html)
(http://i859.photobucket.com/albums/ab154/firehawk068/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/08A91007-CC2F-4833-9D0C-60EF7E4ACC07_zpshbmup5zn.jpg) (http://s859.photobucket.com/user/firehawk068/media/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/08A91007-CC2F-4833-9D0C-60EF7E4ACC07_zpshbmup5zn.jpg.html)
I then used my Auto-Bearing-Packer to fill the bearing cone.
I also cleaned and re-greased the lower bearing.
One thing I noticed. The new upper bearing has an integrated seal on the top of it. The old bearing did not.
(http://i859.photobucket.com/albums/ab154/firehawk068/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/F970D822-5C5F-4EF9-8D83-74042B2883BA_zpshcmp9exa.jpg) (http://s859.photobucket.com/user/firehawk068/media/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/F970D822-5C5F-4EF9-8D83-74042B2883BA_zpshcmp9exa.jpg.html)
(http://i859.photobucket.com/albums/ab154/firehawk068/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/790CE826-7B70-4F4A-813E-1FC1877CBB67_zpsei9lxmu6.jpg) (http://s859.photobucket.com/user/firehawk068/media/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/790CE826-7B70-4F4A-813E-1FC1877CBB67_zpsei9lxmu6.jpg.html)
(http://i859.photobucket.com/albums/ab154/firehawk068/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/787D2968-8F49-4DF0-8010-F6044E763D3F_zpsc9spn7i6.jpg) (http://s859.photobucket.com/user/firehawk068/media/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/787D2968-8F49-4DF0-8010-F6044E763D3F_zpsc9spn7i6.jpg.html)
(http://i859.photobucket.com/albums/ab154/firehawk068/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/E89FD5C3-AEA4-4F4B-9339-4CEF7FD743B5_zpsj4mu5kmf.jpg) (http://s859.photobucket.com/user/firehawk068/media/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/E89FD5C3-AEA4-4F4B-9339-4CEF7FD743B5_zpsj4mu5kmf.jpg.html)
Re-assembled the Steering Stem, and mounted the forks back on the bike.
(http://i859.photobucket.com/albums/ab154/firehawk068/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/91EDBA11-609B-44E0-ADB9-FF3884EACC45_zpslegz4lte.jpg) (http://s859.photobucket.com/user/firehawk068/media/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/91EDBA11-609B-44E0-ADB9-FF3884EACC45_zpslegz4lte.jpg.html)
(http://i859.photobucket.com/albums/ab154/firehawk068/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/EDBE1052-54EC-44A2-AFE5-4FE8A79C55F9_zpsjj10yxuo.jpg) (http://s859.photobucket.com/user/firehawk068/media/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/EDBE1052-54EC-44A2-AFE5-4FE8A79C55F9_zpsjj10yxuo.jpg.html)
Now it was time to fill them, so off come the fork caps/adjusters one last time.
This was the fluid that Robert provided.
(http://i859.photobucket.com/albums/ab154/firehawk068/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/EA3F4C3F-CEE5-491E-9616-FD54DDEB9406_zpsdvtylhcs.jpg) (http://s859.photobucket.com/user/firehawk068/media/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/EA3F4C3F-CEE5-491E-9616-FD54DDEB9406_zpsdvtylhcs.jpg.html)
Since there is no fluid level measurement specified for 1984 FJ, I just used the 14.3 US ounces spec.
(http://i859.photobucket.com/albums/ab154/firehawk068/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/45A4D7E2-FBC8-4723-800F-4574F08AEBAA_zpsuz8k3jaf.jpg) (http://s859.photobucket.com/user/firehawk068/media/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/45A4D7E2-FBC8-4723-800F-4574F08AEBAA_zpsuz8k3jaf.jpg.html)
I got it close, at around 14-1/2.............
(http://i859.photobucket.com/albums/ab154/firehawk068/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/D63E2338-8FCC-4433-AC61-E2D374CBCB74_zps6vfchtox.jpg) (http://s859.photobucket.com/user/firehawk068/media/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/D63E2338-8FCC-4433-AC61-E2D374CBCB74_zps6vfchtox.jpg.html)
After buttoning the forks up, and since it has the stock progressive-rate springs from 1984, I set both the pre-load and damping on Max (3).
I explained to the owners the reasoning on this, and that it would be easy to adjust it back if needed.
I then moved on to the front brake calipers.
Removed all the pieces and old brake pads, and cleaned all the grime and fork oil out of them with an old toothbrush.
Inspected them, and verified that the pistons move like they are supposed to.
(http://i859.photobucket.com/albums/ab154/firehawk068/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/9B50C514-FB66-4DFA-802E-7F8E5794A65F_zpstqzomhxd.jpg) (http://s859.photobucket.com/user/firehawk068/media/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/9B50C514-FB66-4DFA-802E-7F8E5794A65F_zpstqzomhxd.jpg.html)
(http://i859.photobucket.com/albums/ab154/firehawk068/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/687E1B3B-4FEE-4766-86AC-AFAEE38767F9_zpsjptbu9yk.jpg) (http://s859.photobucket.com/user/firehawk068/media/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/687E1B3B-4FEE-4766-86AC-AFAEE38767F9_zpsjptbu9yk.jpg.html)
At this point, I inspected the front wheel bearings, cleaned the seals really good, and put some fresh grease on them.
I assembled the front wheel back on the bike, and un-strapped it from the floor.
It was now sitting back on the front suspension again.
(http://i859.photobucket.com/albums/ab154/firehawk068/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/C0477BC7-1BC6-4D2B-9B8D-74B7CE132D17_zpsritgoe1o.jpg) (http://s859.photobucket.com/user/firehawk068/media/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/C0477BC7-1BC6-4D2B-9B8D-74B7CE132D17_zpsritgoe1o.jpg.html)
(http://i859.photobucket.com/albums/ab154/firehawk068/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/20041923-BC49-413B-AF2B-D32D9B938E8C_zps160xzyt6.jpg) (http://s859.photobucket.com/user/firehawk068/media/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/20041923-BC49-413B-AF2B-D32D9B938E8C_zps160xzyt6.jpg.html)
I then carefully cleaned out the master cylinder reservoir.
There was a bunch of dirt in the bottom.
(http://i859.photobucket.com/albums/ab154/firehawk068/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/F2F2F5C5-90D0-4A75-8AA1-61D96CC0D331_zpsflmadgaa.jpg) (http://s859.photobucket.com/user/firehawk068/media/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/F2F2F5C5-90D0-4A75-8AA1-61D96CC0D331_zpsflmadgaa.jpg.html)
I reassembled the front calipers using new Yamaha factory brake pads, and mounted them back on the fork legs.
(http://i859.photobucket.com/albums/ab154/firehawk068/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/A1610041-8B03-4C12-8597-FE4DBC71B857_zpsqqshb9pt.jpg) (http://s859.photobucket.com/user/firehawk068/media/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/A1610041-8B03-4C12-8597-FE4DBC71B857_zpsqqshb9pt.jpg.html)
(http://i859.photobucket.com/albums/ab154/firehawk068/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/04F9A549-297C-4B0B-9D4F-0131F27706FB_zpsbfva3ymh.jpg) (http://s859.photobucket.com/user/firehawk068/media/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/04F9A549-297C-4B0B-9D4F-0131F27706FB_zpsbfva3ymh.jpg.html)
Using my vacuum bleeder, I flushed the complete front system until fresh fluid ran clear through each bleeder.
(http://i859.photobucket.com/albums/ab154/firehawk068/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/F4218765-D1F2-4658-B937-D32873B0AF4D_zpsazgbasgi.jpg) (http://s859.photobucket.com/user/firehawk068/media/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/F4218765-D1F2-4658-B937-D32873B0AF4D_zpsazgbasgi.jpg.html)
(http://i859.photobucket.com/albums/ab154/firehawk068/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/6AF1A68F-1542-46ED-87D6-A2C2E41F4076_zpsfpw1dnha.jpg) (http://s859.photobucket.com/user/firehawk068/media/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/6AF1A68F-1542-46ED-87D6-A2C2E41F4076_zpsfpw1dnha.jpg.html)
I cleaned up the front fender, and mounted it back on the FJ.
This has to be the most pristine front fender I have ever seen. All the mounting tabs were perfect! Not a crack or deformed plastic anywhere!
(http://i859.photobucket.com/albums/ab154/firehawk068/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/85134B04-BF9A-4A0E-A340-12C8D383CF06_zpsuilo3xa6.jpg) (http://s859.photobucket.com/user/firehawk068/media/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/85134B04-BF9A-4A0E-A340-12C8D383CF06_zpsuilo3xa6.jpg.html)
Looks in way cleaner shape than mine was. With only 2000 less miles than mine.
After your service..... The old beast will be rolling the same as if it just rolled out of the dealership. I am sure Robert will have a huge smile in his face every time he rides.
Fred
Good job Alan. :good:
When you get to the swingarm linkage you will notice that the pivot points do not have the typical needle bearings like the '86 and later FJ's enjoy. The 84/85's just have bushings that absolutely must be clean and greased. If your client wishes you can remove those stupid bushings and install the '86/87 FJ needle bearings in the '84 swing arm which are plug and play.
How about talking him in to some new black ss brake lines? They look oem.
Cheers lad
Quote from: Pat Conlon on November 24, 2016, 10:39:47 PM
Good job Alan. :good:
When you get to the swingarm linkage you will notice that the pivot points do not have the typical needle bearings like the '86 and later FJ's enjoy. The 84/85's just have bushings that absolutely must be clean and greased. If your client wishes you can remove those stupid bushings and install the '86/87 FJ needle bearings in the '84 swing arm which are plug and play.
How about talking him in to some new black ss brake lines? They look oem.
Cheers lad
Honestly, the rear swing-arm and linkage pivots weren't really discussed.
There was an initial list of items that the owners wanted done, and then I added a few items that I considered mandatory as well. A price was agreed on, and then the bike was dropped off.
I did check to make sure there was no roughness or side-play in the rear pivot while I was back there.
Since there was only 8300 miles on it, I didn't think there was a possibility of them being worn yet, and it doesn't come up in the service schedule until 12,000 miles.
I will suggest it as something that should be looked at and maintained going forward. (at this point in time, I don't want to jump too far ahead in the project but the bike is back in the owner's possession and being ridden)
I did make the suggestion about SS-braided brake hoses. I prefer them, but left it up to him to decide.
I did inspect the originals really well. I know they are old, but there is absolutely no signs of cracking, drying out, or failure on any of them. I can't say they look new, cause they are 30+ years old, but they appear fairly new.............
It might have been a different story if this bike had been stored outside in the weather, but luckily it appears at least it was stored in a fairly stable, indoor climate.
After the front end was finished, I turned to the clutch system.
This is exactly how much fluid was left.
(http://i859.photobucket.com/albums/ab154/firehawk068/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/FDDFB144-B997-4D37-9483-DA9C61CCD7C4_zpsvtoqj5es.jpg) (http://s859.photobucket.com/user/firehawk068/media/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/FDDFB144-B997-4D37-9483-DA9C61CCD7C4_zpsvtoqj5es.jpg.html)
The owner had purchased a brand-new slave cylinder to install, so I didn't have to worry about rebuilding the original.
(http://i859.photobucket.com/albums/ab154/firehawk068/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/AC04A14F-33D8-4740-ACE9-1D060BC708BB_zpsihgvsgwv.jpg) (http://s859.photobucket.com/user/firehawk068/media/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/AC04A14F-33D8-4740-ACE9-1D060BC708BB_zpsihgvsgwv.jpg.html)
I cleaned all the dirt out of the master cylinder, installed the new slave, filled and bled the system with fresh fluid.
Works perfectly!
(http://i859.photobucket.com/albums/ab154/firehawk068/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/4DFEBB7B-497E-4FFD-9DAC-119167355B1C_zpsvvrj3nns.jpg) (http://s859.photobucket.com/user/firehawk068/media/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/4DFEBB7B-497E-4FFD-9DAC-119167355B1C_zpsvvrj3nns.jpg.html)
I then turned my attention to the rear of the bike.
While the back wheel was still off, I cleaned the chain with a little kerosene and my grunge-brush.
(http://i859.photobucket.com/albums/ab154/firehawk068/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/B4682FF6-FA4B-4C0F-8B49-3B429A8D812E_zpsz1cv4ycd.jpg) (http://s859.photobucket.com/user/firehawk068/media/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/B4682FF6-FA4B-4C0F-8B49-3B429A8D812E_zpsz1cv4ycd.jpg.html)
It took very little effort, and the chain looks new!
(http://i859.photobucket.com/albums/ab154/firehawk068/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/01883135-791E-4840-B70C-705F2527383B_zpsjjbqabzk.jpg) (http://s859.photobucket.com/user/firehawk068/media/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/01883135-791E-4840-B70C-705F2527383B_zpsjjbqabzk.jpg.html)
Following my rule: (if it comes off the bike, it gets cleaned before it goes back on)
I cleaned the chain guard, and cleaned up the swing-arm of old chain lube, grime, and 20+ years of garage dust.
(http://i859.photobucket.com/albums/ab154/firehawk068/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/92F03007-1B86-44B7-BF31-CAE7A4B064CB_zpsfyqtwi0i.jpg) (http://s859.photobucket.com/user/firehawk068/media/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/92F03007-1B86-44B7-BF31-CAE7A4B064CB_zpsfyqtwi0i.jpg.html)
(http://i859.photobucket.com/albums/ab154/firehawk068/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/C511F81B-FF71-42EC-BD8C-6398648521FE_zpsq7bdns2i.jpg) (http://s859.photobucket.com/user/firehawk068/media/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/C511F81B-FF71-42EC-BD8C-6398648521FE_zpsq7bdns2i.jpg.html)
I then inspected the rear wheel bearings, put some fresh grease on the seals, and mounted the rear wheel back on the bike.
I adjusted the chain tension, and alignment using my chain-tool.
(http://i859.photobucket.com/albums/ab154/firehawk068/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/64223293-9C34-4698-80C6-B1B2F4DC6F8D_zps28itl1gd.jpg) (http://s859.photobucket.com/user/firehawk068/media/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/64223293-9C34-4698-80C6-B1B2F4DC6F8D_zps28itl1gd.jpg.html)
(http://i859.photobucket.com/albums/ab154/firehawk068/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/4B9FD9BF-E02E-4B8A-B7B2-CCC147480979_zpsh2ly9ty2.jpg) (http://s859.photobucket.com/user/firehawk068/media/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/4B9FD9BF-E02E-4B8A-B7B2-CCC147480979_zpsh2ly9ty2.jpg.html)
I lubed the chain at this point.
It's starting to look like a complete bike again, however there was more challenges to come.
(http://i859.photobucket.com/albums/ab154/firehawk068/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/F352BFB5-D2B6-40AC-B27C-270158B694DA_zpsplgep6iu.jpg) (http://s859.photobucket.com/user/firehawk068/media/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/F352BFB5-D2B6-40AC-B27C-270158B694DA_zpsplgep6iu.jpg.html)
(http://i859.photobucket.com/albums/ab154/firehawk068/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/1A3E6ABE-FEA8-4A41-9B94-98201D48C11D_zps5p6flhby.jpg) (http://s859.photobucket.com/user/firehawk068/media/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/1A3E6ABE-FEA8-4A41-9B94-98201D48C11D_zps5p6flhby.jpg.html)
(http://i859.photobucket.com/albums/ab154/firehawk068/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/6A16E5A9-0244-4DBC-A699-D2820998A8F1_zpsrzg4nnti.jpg) (http://s859.photobucket.com/user/firehawk068/media/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/6A16E5A9-0244-4DBC-A699-D2820998A8F1_zpsrzg4nnti.jpg.html)
When the time came to flush/bleed the rear brake system, I ran into trouble.
The caliper pistons would move just fine. I could push one in, and the other one would come out, but I couldn't draw any fluid through the system with the vacuum pump.
Nor could I push any fluid out of either bleeder screw by pushing on the brake lever.
I called Robert and told him the rear master cylinder would have to come off, and either rebuilt or replaced.
When I took the snap-ring, and the pushrod out, it was obvious what the issue was.
The piston was stuck all the way inside the bore, and would not return via the spring.
A sharp rap on the floor and it popped right out.
(http://i859.photobucket.com/albums/ab154/firehawk068/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/DBB6A381-F132-438F-9531-063BAFB36F69_zpsksg2yy7l.jpg) (http://s859.photobucket.com/user/firehawk068/media/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/DBB6A381-F132-438F-9531-063BAFB36F69_zpsksg2yy7l.jpg.html)
The bore didn't look too bad. It just had some stuck-on bits of rubber from where the seals were stuck.
(http://i859.photobucket.com/albums/ab154/firehawk068/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/CE2A6753-D70C-4174-B9BD-D0902C2B7FFD_zpsnrwv7y0n.jpg) (http://s859.photobucket.com/user/firehawk068/media/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/CE2A6753-D70C-4174-B9BD-D0902C2B7FFD_zpsnrwv7y0n.jpg.html)
I used the flex-shaft attachment on my Dremel, and a very worn mini flap-wheel. I used just enough speed to turn it inside the bore, and made a couple passes all the way inside.
(http://i859.photobucket.com/albums/ab154/firehawk068/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/1328C817-D816-47B5-BBF8-FD499CB73C10_zpsppflioma.jpg) (http://s859.photobucket.com/user/firehawk068/media/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/1328C817-D816-47B5-BBF8-FD499CB73C10_zpsppflioma.jpg.html)
It cleaned up perfectly.
I let Robert know to just order the rebuild kit.
(http://i859.photobucket.com/albums/ab154/firehawk068/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/E705AB13-84D5-48D5-ADE5-7DBBCA956D51_zpsammmm2t0.jpg) (http://s859.photobucket.com/user/firehawk068/media/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/E705AB13-84D5-48D5-ADE5-7DBBCA956D51_zpsammmm2t0.jpg.html)
I knew that I still had a bunch of work to do on the bike, so waiting a few days for a rebuild kit wasn't going to be an issue.
I removed the front sub-frame bolts, loosened the rear bolts, and pushed the sub-frame back enough to remove the air-box.
(http://i859.photobucket.com/albums/ab154/firehawk068/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/B45F73C7-3970-4823-AAA0-1760682E6CAC_zpsalgrgy8p.jpg) (http://s859.photobucket.com/user/firehawk068/media/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/B45F73C7-3970-4823-AAA0-1760682E6CAC_zpsalgrgy8p.jpg.html)
Then I removed the rack of carburetors from the engine.
(http://i859.photobucket.com/albums/ab154/firehawk068/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/BB85E4D3-36E7-4981-9408-E7BDD9D68575_zpszuwu0dzs.jpg) (http://s859.photobucket.com/user/firehawk068/media/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/BB85E4D3-36E7-4981-9408-E7BDD9D68575_zpszuwu0dzs.jpg.html)
At this point I noticed that all the overflow and vent hoses were just bundled up underneath the carbs, and weren't routed down behind the case like they are supposed to............ :scratch_one-s_head:
I wasn't sure what I would find once I got inside them? :unknown:
Since this particular FJ already has a 4-into-1 Supertrapp exhaust on it, had someone messed with the jetting at some point also?
I removed all the hoses and the throttle cables, and drained what was left in the fuel bowls.
What came out was a very foul-smelling, orange syrup! :bad:
(http://i859.photobucket.com/albums/ab154/firehawk068/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/6EBFDC2C-6346-4BD1-B7D8-31AE15BE0880_zpsdphfjuri.jpg) (http://s859.photobucket.com/user/firehawk068/media/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/6EBFDC2C-6346-4BD1-B7D8-31AE15BE0880_zpsdphfjuri.jpg.html)
Since I had the carbs off the engine, I took a peek down the intake ports.
Quite a bit of carbon in there.
(http://i859.photobucket.com/albums/ab154/firehawk068/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/F874A126-0367-483A-AF1E-EAA4A48E30D2_zpszwbjfde4.jpg) (http://s859.photobucket.com/user/firehawk068/media/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/F874A126-0367-483A-AF1E-EAA4A48E30D2_zpszwbjfde4.jpg.html)
(http://i859.photobucket.com/albums/ab154/firehawk068/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/7CF49A83-CC40-42FE-A9E3-AC27967DDA42_zpsmvg66thg.jpg) (http://s859.photobucket.com/user/firehawk068/media/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/7CF49A83-CC40-42FE-A9E3-AC27967DDA42_zpsmvg66thg.jpg.html)
This set of carbs was by far the worst I have seen out of everything I have ever worked on!
(http://i859.photobucket.com/albums/ab154/firehawk068/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/CFA61556-2C99-4E93-A99F-736C2BC003B0_zpsodd3mxlm.jpg) (http://s859.photobucket.com/user/firehawk068/media/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/CFA61556-2C99-4E93-A99F-736C2BC003B0_zpsodd3mxlm.jpg.html)
The slides were completely stuck in place.
The Choke pistons wouldn't budge.
The throttle shafts were locked solid!
Everything was completely gummed up with sticky varnish.........................Oh Boy, this is going to be fun!
What a find !!! Nice works, and very detail oriented. It's making me chomp at the bit to get mine, and get started on it. Can't wait. Hopefully next weekend.
I can see I'm going to like it around here. :music:
Going to watch this Thread...Wow awesome Work!
I set up my work table to get started on the carburetors, so that I could lay everything out in neat order as it gets disassembled.
Since I couldn't move any of the moveable bits, I just removed the Diaphragm caps, the springs, and fuel bowls.
(http://i859.photobucket.com/albums/ab154/firehawk068/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/B0274465-2043-4348-B42B-B7EB195D7033_zps0utnhj3d.jpg) (http://s859.photobucket.com/user/firehawk068/media/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/B0274465-2043-4348-B42B-B7EB195D7033_zps0utnhj3d.jpg.html)
Since I don't have access to an Ultrasonic Cleaner that's large enough for a whole rack of carbs, I improvised.
Some of you may laugh at me................but hey, I use what I have most of the time. :flag_of_truce:
My small, cordless Sander uses Velcro-Sanding Pads, so I attached some Velcro strips to the bottom of a storage bin.
(http://i859.photobucket.com/albums/ab154/firehawk068/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/EDCCDA52-46BA-4261-A289-46FABA058F4C_zps6tk6fgul.jpg) (http://s859.photobucket.com/user/firehawk068/media/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/EDCCDA52-46BA-4261-A289-46FABA058F4C_zps6tk6fgul.jpg.html)
It's just large enough for a rack of carbs.
Before separating and stripping the carb bodies, I wanted to remove the bulk of the 20-years of gummy varnish. (or at least loosen it)
Since the Fuel Bowls have a tiny passage in them, I put those in as well.
(http://i859.photobucket.com/albums/ab154/firehawk068/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/9139A23E-40E6-4536-B372-F2A98D8F9BDD_zpsia4oxjb3.jpg) (http://s859.photobucket.com/user/firehawk068/media/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/9139A23E-40E6-4536-B372-F2A98D8F9BDD_zpsia4oxjb3.jpg.html)
I used a mixture of 25% Simple Green, and 75% HOT (just off the stove-boiling) water.
(http://i859.photobucket.com/albums/ab154/firehawk068/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/788ADA36-7FA7-4AB1-870A-41198563135E_zpssk7qkitz.jpg) (http://s859.photobucket.com/user/firehawk068/media/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/788ADA36-7FA7-4AB1-870A-41198563135E_zpssk7qkitz.jpg.html)
I had the carbs in there for a little over an hour. During that time they got about 45 minutes of agitation from the vibrating bath. (the battery pack would last about 15 minutes at a time. I had 2 battery packs to switch out and charge)
Before the bath, the slides would not move (I didn't try to push them out by force) and the butterflies would not budge.
(http://i859.photobucket.com/albums/ab154/firehawk068/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/954A7BB6-CE98-4CB9-B61B-7CB57451090E_zpsm2pdjkoo.jpg) (http://s859.photobucket.com/user/firehawk068/media/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/954A7BB6-CE98-4CB9-B61B-7CB57451090E_zpsm2pdjkoo.jpg.html)
Two of the slides came out in the bath. The other two pushed right out after. The butterflies would now rotate freely. :good2:
Next came more disassembly and cleaning.
(http://i859.photobucket.com/albums/ab154/firehawk068/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/A75D9F7A-DC5B-44DA-83D4-5EEE522E375F_zpsmb6eyj9l.jpg) (http://s859.photobucket.com/user/firehawk068/media/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/A75D9F7A-DC5B-44DA-83D4-5EEE522E375F_zpsmb6eyj9l.jpg.html)
After the initial bath, the choke plungers were still stuck. I didn't want to risk damaging them by trying to yank them out.
My Pressure-Washer also has a Steam-Gun with a fairly tiny nozzle.
Using Distilled-water, I applied the hot steam into the choke passages. This quickly loosened the sticky gum, and the choke plungers pulled right out.
I also used the steam into all the rest of the internal passages to loosen any gummy residue inside.
(http://i859.photobucket.com/albums/ab154/firehawk068/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/86CCCA27-DDB7-41E1-AB12-8115E5E72CE4_zpsm1hpzmwp.jpg) (http://s859.photobucket.com/user/firehawk068/media/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/86CCCA27-DDB7-41E1-AB12-8115E5E72CE4_zpsm1hpzmwp.jpg.html)
(http://i859.photobucket.com/albums/ab154/firehawk068/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/1E7637D7-D50D-445F-B722-292AB3DC674F_zpsrlnemwzi.jpg) (http://s859.photobucket.com/user/firehawk068/media/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/1E7637D7-D50D-445F-B722-292AB3DC674F_zpsrlnemwzi.jpg.html)
(http://i859.photobucket.com/albums/ab154/firehawk068/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/8D875DF8-2B8E-4254-BBF6-DECBAB12CB04_zpsa7uuiosp.jpg) (http://s859.photobucket.com/user/firehawk068/media/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/8D875DF8-2B8E-4254-BBF6-DECBAB12CB04_zpsa7uuiosp.jpg.html)
I made sure to keep everything organized neatly in line (1-through-4), so all the pieces would go back into the carb body they came out of.
(http://i859.photobucket.com/albums/ab154/firehawk068/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/6A743F5C-BC35-48FD-823F-88F8D9EAB19A_zpslb0ksctl.jpg) (http://s859.photobucket.com/user/firehawk068/media/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/6A743F5C-BC35-48FD-823F-88F8D9EAB19A_zpslb0ksctl.jpg.html)
I recently purchased an Ultrasonic Cleaner from Harbor-Freight (more on this later) for this project. It is the larger of the two that they sell, and is large enough for (2) individual carb bodies to fit in (just, but you have to flip them over for complete cleaning) It does have a built-in heater, so I didn't have to heat the water as much before filling.
I wanted to see just how much dirt would come out of (1) of these carbs. :scratch_one-s_head:
I used a mixture of 25% Simple Green HD (the purple stuff this time. it's safer on aluminum), and 75% water.
(http://i859.photobucket.com/albums/ab154/firehawk068/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/B7A9757B-8C76-43FF-BA93-C782AB55F444_zpsaiqzypl8.jpg) (http://s859.photobucket.com/user/firehawk068/media/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/B7A9757B-8C76-43FF-BA93-C782AB55F444_zpsaiqzypl8.jpg.html)
I took the number-two carb body and soaked it in the ultrasonic bath for an hour on each side, resetting the timer every 10 minutes. (this particular model only lets you run the agitator-transducer for 8-minutes at a time...........Cheap!)
Quite a bit of internal material came out!
(http://i859.photobucket.com/albums/ab154/firehawk068/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/478490B4-76A9-4409-A352-2B88F7B30345_zpsmbuu28ap.jpg) (http://s859.photobucket.com/user/firehawk068/media/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/478490B4-76A9-4409-A352-2B88F7B30345_zpsmbuu28ap.jpg.html)
After a clean, hot-water rinse and a blow-dry with compressed air, it is looking super clean! :yahoo:
(http://i859.photobucket.com/albums/ab154/firehawk068/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/45A063D8-CA4F-41E4-B002-99D1BCE44C0D_zpsqkuluhvd.jpg) (http://s859.photobucket.com/user/firehawk068/media/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/45A063D8-CA4F-41E4-B002-99D1BCE44C0D_zpsqkuluhvd.jpg.html)
(http://i859.photobucket.com/albums/ab154/firehawk068/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/0C4E39D2-4B54-4D4B-9E27-5986BAA840C3_zpslbdiyl3r.jpg) (http://s859.photobucket.com/user/firehawk068/media/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/0C4E39D2-4B54-4D4B-9E27-5986BAA840C3_zpslbdiyl3r.jpg.html)
The one on the left hadn't gone through the Ultrasonic Cleaner yet. The one on the right is the one I just finished.
Quite a difference! :good:
(http://i859.photobucket.com/albums/ab154/firehawk068/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/1FDA5C35-7DB9-4F14-95E6-EBA86BAA6DA2_zpsgswh6nco.jpg) (http://s859.photobucket.com/user/firehawk068/media/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/1FDA5C35-7DB9-4F14-95E6-EBA86BAA6DA2_zpsgswh6nco.jpg.html)
Over the next several hours into the evening, I was able to rotate the rest of the carb bodies through the same two-hour ultrasonic bath.
(http://i859.photobucket.com/albums/ab154/firehawk068/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/46F2C1F4-033E-40A7-9EFD-B3C79BCE16C7_zpsikb5s2uu.jpg) (http://s859.photobucket.com/user/firehawk068/media/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/46F2C1F4-033E-40A7-9EFD-B3C79BCE16C7_zpsikb5s2uu.jpg.html)
More to come...........................
love the sander bath.....im gonne call it a sub sonic bath. :wacko1:
Classic tinkering Al.
The following morning, the rebuild kit for the rear master cylinder showed up.
I cleaned, and re-assembled it.
Mounted it back on the FJ, then flushed and bled the system with fresh fluid.
(http://i859.photobucket.com/albums/ab154/firehawk068/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/58394218-B4C6-46EE-AAFB-8934232B644E_zps55pjaggb.jpg) (http://s859.photobucket.com/user/firehawk068/media/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/58394218-B4C6-46EE-AAFB-8934232B644E_zps55pjaggb.jpg.html)
(http://i859.photobucket.com/albums/ab154/firehawk068/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/3ED66FCE-23CB-474C-92FF-00FEFDBD0283_zpsv1hzsgaa.jpg) (http://s859.photobucket.com/user/firehawk068/media/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/3ED66FCE-23CB-474C-92FF-00FEFDBD0283_zpsv1hzsgaa.jpg.html)
(http://i859.photobucket.com/albums/ab154/firehawk068/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/5B2DBBD2-8A73-4B3C-A623-9EDBBBF80A0A_zpshd02w9ow.jpg) (http://s859.photobucket.com/user/firehawk068/media/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/5B2DBBD2-8A73-4B3C-A623-9EDBBBF80A0A_zpshd02w9ow.jpg.html)
(http://i859.photobucket.com/albums/ab154/firehawk068/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/35C01B5D-2780-4C6A-93D4-06590BFB4A30_zpsagx65x81.jpg) (http://s859.photobucket.com/user/firehawk068/media/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/35C01B5D-2780-4C6A-93D4-06590BFB4A30_zpsagx65x81.jpg.html)
It was at this moment in time, as I was about to cycle a bunch of the smaller carb parts through the Ultrasonic Cleaner, that I realized it wouldn't turn on.............. :scratch_one-s_head:
So, I made the journey back to Harbor-Freight with my receipt to exchange it.
Get the new one home. Add cleaning solution. Turn it on........................ It works for about 5 seconds, then I hear a distinct clunk inside the machine as it stops "Humming" :dash2:
Emptied it, and took the bottom cover off. The vibrator Transducer had detached itself from the bottom of the tank (it appeared to be epoxied on)
I put everything back in the box, and made the journey back to Harbor-freight to return it (this time to get my money back)
Do yourselves a favor..............If you are ever considering buying one of these...............Don't! :negative:
I put all the small brass parts in a jar of carb cleaner, and used my mini-sander strapped to the side of it for about 15 minutes.
Then let them soak for about an hour, then another 15 minutes of sander.
They came out clean.
I blew compressed air through them all, and verified all the tiny little holes were clean and clear.
(http://i859.photobucket.com/albums/ab154/firehawk068/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/7559928E-0B73-4194-AD14-6F7B5CC89FB8_zpsegtuljwa.jpg) (http://s859.photobucket.com/user/firehawk068/media/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/7559928E-0B73-4194-AD14-6F7B5CC89FB8_zpsegtuljwa.jpg.html)
I cleaned the idle-mixture needle screws by hand and brush, as well as the slides and needles by hand.
Using the new SS-screw and o-ring kit, and the new inlet needle/seats supplied by Randy, I assembled the carbs.
(http://i859.photobucket.com/albums/ab154/firehawk068/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/5BEB7E70-3568-42DC-A35A-41106B339EE4_zpsgdv8td5s.jpg) (http://s859.photobucket.com/user/firehawk068/media/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/5BEB7E70-3568-42DC-A35A-41106B339EE4_zpsgdv8td5s.jpg.html)
(http://i859.photobucket.com/albums/ab154/firehawk068/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/296F9509-B4D0-49C7-BF1F-A3818A26C841_zpsmnrgek5u.jpg) (http://s859.photobucket.com/user/firehawk068/media/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/296F9509-B4D0-49C7-BF1F-A3818A26C841_zpsmnrgek5u.jpg.html)
(http://i859.photobucket.com/albums/ab154/firehawk068/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/8D93CB2C-E130-4BEC-B3CE-CEDCDA9ADD43_zpsqp3gutcr.jpg) (http://s859.photobucket.com/user/firehawk068/media/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/8D93CB2C-E130-4BEC-B3CE-CEDCDA9ADD43_zpsqp3gutcr.jpg.html)
(http://i859.photobucket.com/albums/ab154/firehawk068/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/9C845E0A-4E67-4F1C-83E5-CD32BE13AFB2_zpsnux7b8qz.jpg) (http://s859.photobucket.com/user/firehawk068/media/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/9C845E0A-4E67-4F1C-83E5-CD32BE13AFB2_zpsnux7b8qz.jpg.html)
I verified that the choke valves, the slides, and butterflies all operated freely as they should.
(http://i859.photobucket.com/albums/ab154/firehawk068/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/A2C62AC3-E715-454A-AC43-4A65005F9CE0_zpsjzlvpj9g.jpg) (http://s859.photobucket.com/user/firehawk068/media/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/A2C62AC3-E715-454A-AC43-4A65005F9CE0_zpsjzlvpj9g.jpg.html)
I lubed the lower throttle cables, and installed them back on the carb rack.
I then set the idle-mixture screws using the "Fingernail" method, and did my best "Bench-sync" of the butterflies by using my calibrated eye-ball measuring tool..............
(http://i859.photobucket.com/albums/ab154/firehawk068/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/0DB010D6-BF42-4CAC-910D-A6883DF51719_zps0v0uk0nu.jpg) (http://s859.photobucket.com/user/firehawk068/media/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/0DB010D6-BF42-4CAC-910D-A6883DF51719_zps0v0uk0nu.jpg.html)
I set these aside, feeling confident that they are as clean as they could possibly be, and ready for use.
I then moved on to the valve clearance check.
Removed the cam-cover, and was immediately struck by the cleanliness of the inside of this low-mileage engine!
(http://i859.photobucket.com/albums/ab154/firehawk068/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/14CBF087-79D9-4743-B150-1049B152B688_zpsrmols1bg.jpg) (http://s859.photobucket.com/user/firehawk068/media/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/14CBF087-79D9-4743-B150-1049B152B688_zpsrmols1bg.jpg.html)
(http://i859.photobucket.com/albums/ab154/firehawk068/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/F92C4C5C-B195-47B5-B0D2-AC9979FB5C32_zpslukwfcub.jpg) (http://s859.photobucket.com/user/firehawk068/media/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/F92C4C5C-B195-47B5-B0D2-AC9979FB5C32_zpslukwfcub.jpg.html)
This is the point where I encountered another set-back......................
I searched..........and searched...............and searched........
I could not find my feeler gauges for doing valve checks. Where the heck did I put those? :scratch_one-s_head:
I found my ring of feeler gauges, but it was missing all the smallest ones that one would use for valve clearances.......... :unknown:
DANG! After losing more wrench-time to searching, I decided it would be best to go out and purchase a new set..............So I did.
First round of measuring done..................I used inches, as that's what I'm used to.
I was hoping that with only 8300 miles on the bike, there wouldn't be many adjustments needed..............
Turns out HALF of them were out of spec.
(http://i859.photobucket.com/albums/ab154/firehawk068/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/F3CA80FA-F4CA-4C17-BDD1-CA66AF888CB0_zps9a7z9uhq.jpg) (http://s859.photobucket.com/user/firehawk068/media/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/F3CA80FA-F4CA-4C17-BDD1-CA66AF888CB0_zps9a7z9uhq.jpg.html)
I made a phone call to Lee C. (Yes, the legendary Lee C.) to ask to borrow his valve bucket hold-down tool.
He generously offered to bring it by the following morning........
With that in mind, I went to the tool cabinet to get out my digital micrometer (I use it to measure the shims in case the markings have been wore off, or are mis-marked) and check that I have a good battery for it.
I opened the box, and what do I find?.........................
I find that I had stashed my valve-check feeler gauges in with the micrometer the last time I had done mine..................DOH! At least now I have two sets....... :blush:
(http://i859.photobucket.com/albums/ab154/firehawk068/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/A79D458D-2EC1-4C7B-84DF-EADC5BBDDDF2_zpsw8s9d4hz.jpg) (http://s859.photobucket.com/user/firehawk068/media/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/A79D458D-2EC1-4C7B-84DF-EADC5BBDDDF2_zpsw8s9d4hz.jpg.html)
More tomorrow.............................
Quote from: Firehawk068 on December 08, 2016, 11:16:24 PM
DOH! At least now I have two sets....... :blush:
Phew! It's good to feel I'm not alone.... along with my 2 OEM choke cables.... 2 tap & die sets .... 2 cans or tubes of just about everything .... :scratch_one-s_head:
The next morning Lee C. shows up with the tool for me to borrow.
We spent some time chatting and catching up.
He was also curious about this low-mileage '84, so we spent a few minutes looking it over.
I had previously promised him the next time he came over I would show him my Rifles, so we spent some time talking about guns, hunting, and looking over my long-gun collection.
When it was time for him to go, I made my way back out to the garage and the FJ once again.
Started by removing and taking measurement of all the shims in those positions that were out of spec.
(http://i859.photobucket.com/albums/ab154/firehawk068/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/97CF082E-A8B4-4F2F-A31A-9C1F5BB5D46E_zpsll3e4bnv.jpg) (http://s859.photobucket.com/user/firehawk068/media/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/97CF082E-A8B4-4F2F-A31A-9C1F5BB5D46E_zpsll3e4bnv.jpg.html)
(http://i859.photobucket.com/albums/ab154/firehawk068/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/706AA5F1-0503-461A-A870-5B78216086E0_zpslwsu1sdi.jpg) (http://s859.photobucket.com/user/firehawk068/media/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/706AA5F1-0503-461A-A870-5B78216086E0_zpslwsu1sdi.jpg.html)
(http://i859.photobucket.com/albums/ab154/firehawk068/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/9FB349F3-812E-4A93-ACDB-8292A036280A_zps4mznoai2.jpg) (http://s859.photobucket.com/user/firehawk068/media/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/9FB349F3-812E-4A93-ACDB-8292A036280A_zps4mznoai2.jpg.html)
After a bunch of math, I figured out what shims were needed, and what shims I had to work with. :mail1:
I also figured out that taking measurements in inches, then converting them to metric, and back again was a waste of time. My feeler gauges have both readings on them, so at this point I decided to just stick to metric measurements.
(http://i859.photobucket.com/albums/ab154/firehawk068/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/B2D457D9-9CA1-4C3E-85A2-78DD723CA29A_zpspuguoo8p.jpg) (http://s859.photobucket.com/user/firehawk068/media/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/B2D457D9-9CA1-4C3E-85A2-78DD723CA29A_zpspuguoo8p.jpg.html)
I moved around the shims that I could move, and checked my own stash of shims for spares that I could use. (turns out I only had one that was useful)
Did the recalculating, and it turns out that it needed exactly 2 shims that I didn't have.
(http://i859.photobucket.com/albums/ab154/firehawk068/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/4EA6556C-501E-4045-BECE-4957A77D3A2E_zps3w5omqas.jpg) (http://s859.photobucket.com/user/firehawk068/media/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/4EA6556C-501E-4045-BECE-4957A77D3A2E_zps3w5omqas.jpg.html)
I called to let Bob know what was needed.
He did some calling around, but nobody had the sizes we needed.
I also did some calling around. I checked with Lee. I checked with Barry. I also called around to some Toyota and Honda dealers, as well as a bunch of engine and cylinder head machine shops. There were a couple people that had the 265 shim, but absolutely no one in town had a 260 shim..........None!
The decision was made to just order them from Randy and we would wait for them.....................................DARN! I was getting excited for the bike, and was hoping to have it running by the following day............ :nea:
I still had some other things that I could finish up on the bike in the meantime.
I removed the carb intake boots to replace the O-rings on those.
(http://i859.photobucket.com/albums/ab154/firehawk068/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/66E2B2FD-4C03-40A9-BFE7-7C2F1C48CE09_zpsnatsngzv.jpg) (http://s859.photobucket.com/user/firehawk068/media/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/66E2B2FD-4C03-40A9-BFE7-7C2F1C48CE09_zpsnatsngzv.jpg.html)
(http://i859.photobucket.com/albums/ab154/firehawk068/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/B138EEDA-DC7B-4689-A63E-7B7F8144E7A6_zps5tqbuzss.jpg) (http://s859.photobucket.com/user/firehawk068/media/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/B138EEDA-DC7B-4689-A63E-7B7F8144E7A6_zps5tqbuzss.jpg.html)
Gave the boots and the heat-shield a good washing.
(http://i859.photobucket.com/albums/ab154/firehawk068/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/8F952F4E-2C76-4A30-B1BA-C0758FEF75D7_zpsr1op5wgf.jpg) (http://s859.photobucket.com/user/firehawk068/media/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/8F952F4E-2C76-4A30-B1BA-C0758FEF75D7_zpsr1op5wgf.jpg.html)
The engine mounting surface cleaned up nicely using a rag soaked with brake-cleaner.
(http://i859.photobucket.com/albums/ab154/firehawk068/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/43BA5035-7562-4473-927A-72482084B3CD_zpsuh8n06y4.jpg) (http://s859.photobucket.com/user/firehawk068/media/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/43BA5035-7562-4473-927A-72482084B3CD_zpsuh8n06y4.jpg.html)
Using the new O-rings, I mounted the items back on the engine.
(http://i859.photobucket.com/albums/ab154/firehawk068/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/054A34F9-1C14-4E69-9874-729BA820F3A0_zpsbbu8wp0k.jpg) (http://s859.photobucket.com/user/firehawk068/media/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/054A34F9-1C14-4E69-9874-729BA820F3A0_zpsbbu8wp0k.jpg.html)
(http://i859.photobucket.com/albums/ab154/firehawk068/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/2ACCF896-6E5D-4981-830E-678D3B9EA11E_zpsvy7eqfys.jpg) (http://s859.photobucket.com/user/firehawk068/media/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/2ACCF896-6E5D-4981-830E-678D3B9EA11E_zpsvy7eqfys.jpg.html)
At this time, I mounted the rack of carbs back on the engine.
I made sure to route all the hoses down behind the engine in their proper location.
(http://i859.photobucket.com/albums/ab154/firehawk068/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/E02805EB-0865-4D7D-9BEE-3B0EAA5497EC_zpsfvon0dmd.jpg) (http://s859.photobucket.com/user/firehawk068/media/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/E02805EB-0865-4D7D-9BEE-3B0EAA5497EC_zpsfvon0dmd.jpg.html)
I also cleaned the air-box, and reinstalled that as well.
(http://i859.photobucket.com/albums/ab154/firehawk068/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/5080B07D-080A-41B8-8404-B400DD4EF0AA_zpstidyqvsm.jpg) (http://s859.photobucket.com/user/firehawk068/media/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/5080B07D-080A-41B8-8404-B400DD4EF0AA_zpstidyqvsm.jpg.html)
(http://i859.photobucket.com/albums/ab154/firehawk068/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/8C5BC2C9-EB67-4D7A-AADD-7B50D7915F6C_zps3mhfk4a2.jpg) (http://s859.photobucket.com/user/firehawk068/media/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/8C5BC2C9-EB67-4D7A-AADD-7B50D7915F6C_zps3mhfk4a2.jpg.html)
I washed the dust off the cam cover, and set it on top just to keep anything from accidentally falling in there until the shims arrive.
(http://i859.photobucket.com/albums/ab154/firehawk068/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/DC7AAF7E-F6DB-4178-87E1-D267F285D715_zps3g20x2ya.jpg) (http://s859.photobucket.com/user/firehawk068/media/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/DC7AAF7E-F6DB-4178-87E1-D267F285D715_zps3g20x2ya.jpg.html)
I unfolded the new gasket out of the package, and laid it out on the bench, and installed the new grommets on the bolts.
(http://i859.photobucket.com/albums/ab154/firehawk068/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/2CA14149-F884-45E9-B302-59966F0893A7_zps8rl551bh.jpg) (http://s859.photobucket.com/user/firehawk068/media/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/2CA14149-F884-45E9-B302-59966F0893A7_zps8rl551bh.jpg.html)
Drained the oil, and put the new cartridge filter on.
(http://i859.photobucket.com/albums/ab154/firehawk068/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/AF054198-64FB-480F-A296-9561F58A6178_zps6hull11l.jpg) (http://s859.photobucket.com/user/firehawk068/media/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/AF054198-64FB-480F-A296-9561F58A6178_zps6hull11l.jpg.html)
Lubed the upper throttle cables, and the choke cable.
(http://i859.photobucket.com/albums/ab154/firehawk068/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/F72428BA-48E8-4F2F-8A19-85E12C1D0300_zpsvtghqud0.jpg) (http://s859.photobucket.com/user/firehawk068/media/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/F72428BA-48E8-4F2F-8A19-85E12C1D0300_zpsvtghqud0.jpg.html)
Also fixed the right rear turn signal stalk. The owner provided me with a new one.
At some point, someone had cut the original one shorter......... :unknown:
(http://i859.photobucket.com/albums/ab154/firehawk068/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/7AAAEEF5-B5FD-453D-9F58-0ABB6F38209A_zpsdjrprek3.jpg) (http://s859.photobucket.com/user/firehawk068/media/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/7AAAEEF5-B5FD-453D-9F58-0ABB6F38209A_zpsdjrprek3.jpg.html)
(http://i859.photobucket.com/albums/ab154/firehawk068/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/72061E11-73C2-4D83-892B-C1CBB4577B0B_zps4pi7fbwy.jpg) (http://s859.photobucket.com/user/firehawk068/media/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/72061E11-73C2-4D83-892B-C1CBB4577B0B_zps4pi7fbwy.jpg.html)
Double-checked that I had lubed the chain................At this point, I was running out of things that we discussed to do on the bike.
(http://i859.photobucket.com/albums/ab154/firehawk068/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/A515CBE8-7437-4A7E-BBE7-92FBA33F6619_zpslhcgeyv3.jpg) (http://s859.photobucket.com/user/firehawk068/media/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/A515CBE8-7437-4A7E-BBE7-92FBA33F6619_zpslhcgeyv3.jpg.html)
When the bike was dropped off, it came with (2) fuel petcocks. One mounted to the tank, and another used one in the small box of parts that was supplied.
Neither one was useable.
The one that was mounted to the tank already has the fuel nipple loose. (it pulls right out easily) It also would flow all the time, regardless of which position the lever was in.........No good.
(http://i859.photobucket.com/albums/ab154/firehawk068/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/A7E26A97-986E-4CD3-AD04-5E74322FF3F2_zpsdhnryhw4.jpg) (http://s859.photobucket.com/user/firehawk068/media/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/A7E26A97-986E-4CD3-AD04-5E74322FF3F2_zpsdhnryhw4.jpg.html)
The other used one was missing the fuel nipple altogether, and just had a short piece of fuel hose jammed into the hole. It too would flow regardless of where the lever is..............No good.
(http://i859.photobucket.com/albums/ab154/firehawk068/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/D3D699C2-3AA7-4FE9-B9B2-2D33D4B3910B_zpsvb6jigxo.jpg) (http://s859.photobucket.com/user/firehawk068/media/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/D3D699C2-3AA7-4FE9-B9B2-2D33D4B3910B_zpsvb6jigxo.jpg.html)
I called Bob to give him the bad news about the petcocks, and that a new one would need to be sourced.
The decision was made to get a safety-wired one from Randy, and that it would arrive with the needed shims.
This was as far as I could go until those parts arrived..............
Getting this FJ running would have to wait another week, until the following weekend.
I used this down-time to pop a couple questions up to the forum.
Such as : "Is this the proper fuel hose routing for a gravity-feed FJ?"
(http://i859.photobucket.com/albums/ab154/firehawk068/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/06B33FCB-7A60-4A29-8ADA-6FDCD5C8CA19_zpsfad18dtm.jpg) (http://s859.photobucket.com/user/firehawk068/media/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/06B33FCB-7A60-4A29-8ADA-6FDCD5C8CA19_zpsfad18dtm.jpg.html)
And : "Is this where this piece goes, that I found laying on the intake boots?"
(http://i859.photobucket.com/albums/ab154/firehawk068/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/74DB835C-6AAA-4E45-BF71-B8C27B3BEE57_zpsc81nkote.jpg) (http://s859.photobucket.com/user/firehawk068/media/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/74DB835C-6AAA-4E45-BF71-B8C27B3BEE57_zpsc81nkote.jpg.html)
(http://i859.photobucket.com/albums/ab154/firehawk068/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/14D32E88-2660-4D2D-9681-3172CABB3AE4_zpsbthgzaoq.jpg) (http://s859.photobucket.com/user/firehawk068/media/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/14D32E88-2660-4D2D-9681-3172CABB3AE4_zpsbthgzaoq.jpg.html)
More to come, as the project comes to a close..............
Firehawk068 had mentioned to me previously that he was gonna be cleaning up an 84 FJ "barn-find". Since I own an 84 FJ, I was curious as to what he was gonna be working with, and what he was gonna do.
So I went to see Firehawk068 a.k.a Alan. The bike did look good, tho a bit tarnished from lack of use. ...but solid, and mostly OEM.
The second thing that I noticed was that Alan's approach to this project involved a lot of thinking ahead, while his hands were still clean.
As his hands started getting soiled, his methodical and logical steps were very well organized. It was a pleasure to be able to see, all laid out, his systematic movements, and his attention to detail.
He also has an impressive layout of tools.....tools of high quality.
When Alan gets finished, the owner of this particular 1984 FJ1100 is gonna have a jewel of a bike, both cosmetically and mechanically!!
My final impression?? Firehawk068 for President of the USA!!
Lee Carkenord Denver CO 84 FJ1100
There might be a few exaggerations in there.......................
Could've been more like an organized mess.... :unknown:
As far as President goes...............Possibly organize a Rally perhaps................Lead the Country? Not a chance! :flag_of_truce:
Alan, I am really enjoying seeing what you are doing. I am more than ever inspired to get back out to my garage to continue bringing my '86 back to its original glory!
Thank you. You are doing a great job!
Dean
I just realized that I never finished up this thread.................Sorry, I've had a TON going on around here lately. :flag_of_truce:
:Facepalm:
The new Safety-wired Petcock and required shims arrived from Randy with no issues.
I picked these items up from JD (the owner) on my lunch-break, as I found out he works right around the corner from me.
I got to work that evening replacing the last two shims, and made a final sheet with all the current measured clearances.
(http://i859.photobucket.com/albums/ab154/firehawk068/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/551C59C3-322C-47EC-A404-8FF987FC5F85_zpsw8lyqxes.jpg) (http://s859.photobucket.com/user/firehawk068/media/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/551C59C3-322C-47EC-A404-8FF987FC5F85_zpsw8lyqxes.jpg.html)
I used a tiny bit of 3M Weatherstrip+Gasket adhesive on the corners, and stuck the new gasket to the cam cover.
(http://i859.photobucket.com/albums/ab154/firehawk068/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/A42F03C9-6982-4685-99DC-860AB05B76EA_zpshmeodqw2.jpg) (http://s859.photobucket.com/user/firehawk068/media/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/A42F03C9-6982-4685-99DC-860AB05B76EA_zpshmeodqw2.jpg.html)
Bolted that back on the engine, and used a bit of the same adhesive to glue this piece back into position on the heat-shield.
(http://i859.photobucket.com/albums/ab154/firehawk068/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/F7FE780E-CF98-406D-9B51-38952200A570_zpsazv3cxzu.jpg) (http://s859.photobucket.com/user/firehawk068/media/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/F7FE780E-CF98-406D-9B51-38952200A570_zpsazv3cxzu.jpg.html)
(http://i859.photobucket.com/albums/ab154/firehawk068/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/55EFD063-3837-4F1A-9CEF-7A7F099124F3_zpsqvfermjg.jpg) (http://s859.photobucket.com/user/firehawk068/media/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/55EFD063-3837-4F1A-9CEF-7A7F099124F3_zpsqvfermjg.jpg.html)
Re-connected the throttle and choke cables, and connected all the spark-plug wires.
This baby is almost ready!
(http://i859.photobucket.com/albums/ab154/firehawk068/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/3E87F48D-90A4-4B27-B183-A126506071BD_zps3kret6cm.jpg) (http://s859.photobucket.com/user/firehawk068/media/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/3E87F48D-90A4-4B27-B183-A126506071BD_zps3kret6cm.jpg.html)
When I tried to remove the original petcock from the fuel tank, the screws were so stubborn that I had to cut a slot in them to assist in removal.
This certainly wouldn't do to install the new one, so a quick trip to ACE Hardware for some stainless-steel fasteners.
(http://i859.photobucket.com/albums/ab154/firehawk068/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/60998AE9-B904-4392-AEB5-3FDCC80F9CF6_zpsmgazrtua.jpg) (http://s859.photobucket.com/user/firehawk068/media/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/60998AE9-B904-4392-AEB5-3FDCC80F9CF6_zpsmgazrtua.jpg.html)
I cleaned the mating surface on the fuel tank really well, and removed a couple burrs that were on there.
(http://i859.photobucket.com/albums/ab154/firehawk068/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/D2D0D600-FD35-4C61-BDE7-B411EF6832D8_zpsularwgls.jpg) (http://s859.photobucket.com/user/firehawk068/media/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/D2D0D600-FD35-4C61-BDE7-B411EF6832D8_zpsularwgls.jpg.html)
Using all new gaskets, installed the new fuel petcock.
(http://i859.photobucket.com/albums/ab154/firehawk068/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/0495B707-8379-4FF9-98BC-02203DA6C914_zps7d7pawgi.jpg) (http://s859.photobucket.com/user/firehawk068/media/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/0495B707-8379-4FF9-98BC-02203DA6C914_zps7d7pawgi.jpg.html)
(http://i859.photobucket.com/albums/ab154/firehawk068/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/D3BA208F-B73C-4EA9-B195-A4915972D17A_zpswqrzig8i.jpg) (http://s859.photobucket.com/user/firehawk068/media/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/D3BA208F-B73C-4EA9-B195-A4915972D17A_zpswqrzig8i.jpg.html)
At this point, it was getting late. Too late in fact to fire up the bike and run it..........................This would have to wait until the next day.
I was getting really anxious at this point....................So many questions were running through my head!
Is the engine in good shape after sitting for so long?
Were my carburetor cleaning/rebuilding skills, and bench-sync procedures up to par?
Had there been any previous engine damage, or ignition/electrical issue which led to this bike being parked for such a long time?
Will all the brakes/hydraulics work properly?
The suspense was killing me! :wacko3:
There was only one item left on the bike at this point, and that was "Fill the engine with oil"
I decided to leave this until the following day, so I set the oil container on top of the bike to remind me and called it a night.
(http://i859.photobucket.com/albums/ab154/firehawk068/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/B4A93C37-13F0-4165-918B-C24E542E6D4C_zpssr4h1xi2.jpg) (http://s859.photobucket.com/user/firehawk068/media/Misc%20Motorcycle%20Stuff/1984%20FJ1100%20barn%20find%20ressurection/B4A93C37-13F0-4165-918B-C24E542E6D4C_zpssr4h1xi2.jpg.html)
Good oil strategy.
Another Fj back from beyond.
All hail Al
Just started on an 86 that sat since 2003. Following this thread will be VERY helpful!