I found this mostly complete 84 FJ1100 on Craigslist last week for $600. So it followed me home (in the trailer) so I had to do something with it. First order of business was to check the oil and it had some in it. Then I pulled the tank and moved the air cleaner back a little and hit it with some starting fluid. I heard it run on all 4 so I knew I had a runner.
(http://i1379.photobucket.com/albums/ah156/jdvorchak/84%20FJ1100/IMG_13881_zpsqlokocs1.jpg) (http://s1379.photobucket.com/user/jdvorchak/media/84%20FJ1100/IMG_13881_zpsqlokocs1.jpg.html)
Both front master cylinders were pretty corroded. A few minutes in the sand blasting cabinet and some "Roll Bar" paint and I think they turned out good:
(http://i1379.photobucket.com/albums/ah156/jdvorchak/84%20FJ1100/7CC01F90-4BB0-48FE-908B-C1526F16786C_zpslxpyk18x.jpg) (http://s1379.photobucket.com/user/jdvorchak/media/84%20FJ1100/7CC01F90-4BB0-48FE-908B-C1526F16786C_zpslxpyk18x.jpg.html)
(http://i1379.photobucket.com/albums/ah156/jdvorchak/84%20FJ1100/15CD6B98-097F-4E55-BF38-1E89EA18FF73_zpsqbbkrnm6.jpg) (http://s1379.photobucket.com/user/jdvorchak/media/84%20FJ1100/15CD6B98-097F-4E55-BF38-1E89EA18FF73_zpsqbbkrnm6.jpg.html)
I pulled the carbs and un-ganged them for a carb dip soak for a few hours each. They weren't that bad! Only the idle jets and starting circuits were plugged. New O-rings and put them back on the bike for the first test with gasoline. After I filled the carbs, with my IV aux tank, the bike started easily and ran on choke. When I was bench syncing the carbs I may have guessed wrong and have idle screws closed too much so it won't idle with choke off.
(http://i1379.photobucket.com/albums/ah156/jdvorchak/84%20FJ1100/2C02EAA2-B84C-4A8B-BE49-626EB5921289_zpsfdfvtv6a.jpg) (http://s1379.photobucket.com/user/jdvorchak/media/84%20FJ1100/2C02EAA2-B84C-4A8B-BE49-626EB5921289_zpsfdfvtv6a.jpg.html)
Safety wired the fuel petcock, which appears to be working and not leaking!
(http://i1379.photobucket.com/albums/ah156/jdvorchak/84%20FJ1100/8B3CD970-8880-49A0-ADED-82B9DBE18E70_zpsbermt0wt.jpg) (http://s1379.photobucket.com/user/jdvorchak/media/84%20FJ1100/8B3CD970-8880-49A0-ADED-82B9DBE18E70_zpsbermt0wt.jpg.html)
Comments welcome..
I never liked the way they look while I'm working on them:
(http://i1379.photobucket.com/albums/ah156/jdvorchak/84%20FJ1100/AFB002CA-2073-484C-A2DC-0683CD159E6C_zpsqab8xpzb.jpg) (http://s1379.photobucket.com/user/jdvorchak/media/84%20FJ1100/AFB002CA-2073-484C-A2DC-0683CD159E6C_zpsqab8xpzb.jpg.html)
I don't know if you can see it but the clutch cover is cracked and leaking where the brake pedal hit it. A little white squiggly line visible just above the pedal pad. Obviously from a mishap one of the PO had. When I had the pedal off, to remove the rear MC from cleaning/rebuild, I straightened the pedal. It was right up next to the clutch cover.
I have a new gasket on order and one of my sons is a professional welder. I'll see if he can weld the crack.
(http://i1379.photobucket.com/albums/ah156/jdvorchak/84%20FJ1100/CF91A4AB-AE40-45C3-82A7-56C380F76B46_zpsd4msq6uc.jpg) (http://s1379.photobucket.com/user/jdvorchak/media/84%20FJ1100/CF91A4AB-AE40-45C3-82A7-56C380F76B46_zpsd4msq6uc.jpg.html)
What the clutch assembly looks like
(http://i1379.photobucket.com/albums/ah156/jdvorchak/84%20FJ1100/1C035CC2-DA4C-4CB0-ADA6-BF4CB87719C1_zpsqpyrpemp.jpg) (http://s1379.photobucket.com/user/jdvorchak/media/84%20FJ1100/1C035CC2-DA4C-4CB0-ADA6-BF4CB87719C1_zpsqpyrpemp.jpg.html)
Inside of the clutch cover. The big thing in the middle is called a "breather". I've never seen anything like it. The crack/hole is in the lower right:
(http://i1379.photobucket.com/albums/ah156/jdvorchak/84%20FJ1100/856238E0-7DE2-4F5C-9432-3C1CDB6CA8A8_zpst6ldqwh2.jpg) (http://s1379.photobucket.com/user/jdvorchak/media/84%20FJ1100/856238E0-7DE2-4F5C-9432-3C1CDB6CA8A8_zpst6ldqwh2.jpg.html)
A closer look at the damage
(http://i1379.photobucket.com/albums/ah156/jdvorchak/84%20FJ1100/421BB261-9020-4A08-832E-B05A6F714D46_zpsygvg88so.jpg) (http://s1379.photobucket.com/user/jdvorchak/media/84%20FJ1100/421BB261-9020-4A08-832E-B05A6F714D46_zpsygvg88so.jpg.html)
What the damage looks like from the outside:
(http://i1379.photobucket.com/albums/ah156/jdvorchak/84%20FJ1100/FA67B770-D3A6-4AAD-9F10-D9816C1057C5_zpshxbh3ogq.jpg) (http://s1379.photobucket.com/user/jdvorchak/media/84%20FJ1100/FA67B770-D3A6-4AAD-9F10-D9816C1057C5_zpshxbh3ogq.jpg.html)
I'm sending it to work with my middle son. He is a body man but has a custom motorcycle shop across the street. He said he'd take it over there and get their take on it.
Wish me luck because I can't seem to find that cover anywhere.
Quote from: jdvorchak on July 02, 2017, 01:38:37 PM
Wish me luck because I can't seem to find that cover anywhere.
If that aluminum deforms under the heat of welding, you will not get a gasket seal.
There some on eBay right now. I counted 5 but here are 3:
http://www.ebay.com/itm/Yamaha-XJR-1200-1300-FJ-1200-Engine-Clutch-Case-Cover-/252718353147?hash=item3ad7300afb:g:nY4AAOSwEzxYdPmO&vxp=mtr (http://www.ebay.com/itm/Yamaha-XJR-1200-1300-FJ-1200-Engine-Clutch-Case-Cover-/252718353147?hash=item3ad7300afb:g:nY4AAOSwEzxYdPmO&vxp=mtr)
http://www.ebay.com/itm/Yamaha-XJR-1200-1300-FJ-1200-Engine-Clutch-Case-Cover-/262912213675?hash=item3d36ca02ab:g:Nh4AAOSwWxNY2RWn&vxp=mtr (http://www.ebay.com/itm/Yamaha-XJR-1200-1300-FJ-1200-Engine-Clutch-Case-Cover-/262912213675?hash=item3d36ca02ab:g:Nh4AAOSwWxNY2RWn&vxp=mtr)
http://www.ebay.com/itm/Yamaha-XJR-1200-1300-FJ-1200-Engine-Clutch-Case-Cover-/252767316541?hash=item3ada1b2a3d:g:GWYAAOSwTuJYoF8B&vxp=mtr (http://www.ebay.com/itm/Yamaha-XJR-1200-1300-FJ-1200-Engine-Clutch-Case-Cover-/252767316541?hash=item3ada1b2a3d:g:GWYAAOSwTuJYoF8B&vxp=mtr)
Did you ask Randy @ RPM? I'll bet he has something.
In addition Bob W has quite a few FJ parts for sale: http://www.fjowners.com/index.php?topic=16433.0 (http://www.fjowners.com/index.php?topic=16433.0)
Just trying to help.
Quote from: jdvorchak on July 02, 2017, 01:38:37 PM
Wish me luck because I can't seem to find that cover anywhere.
Isn't this what your after
http://rpmracingca.com/proddetail.asp?prod=OuterClutchRing (http://rpmracingca.com/proddetail.asp?prod=OuterClutchRing)
The cover will weld up just fine. The trick is getting the contamination out of the crack. I learned this from Randy. Dino oil will burn off to carbon and the weld puddle will reject it. Synthetic will not and just weep out making it difficult to fuse the material. A good welder will fix it for you.
Quote from: jdvorchak on July 02, 2017, 01:38:37 PMInside of the clutch cover. The big thing in the middle is called a "breather". I've never seen anything like it. The crack/hole is in the lower right
I'm sending it to work with my middle son. He is a body man but has a custom motorcycle shop across the street. He said he'd take it over there and get their take on it.
Wish me luck because I can't seem to find that cover anywhere.
jdvorchak,
If you want to get a welded repair on the crack, your best bet in to have a patch fully welded over the crack on the inside, to seal in the oil. The patch is welded onto clean, smooth metal then. On the outside, fill in the crack with welding material, then power-sand smoothly, for appearances. That is what an ace welder did for me, with excellent results.
.
Quote from: jdvorchak on July 02, 2017, 01:38:37 PM
What the clutch assembly looks like
(http://i1379.photobucket.com/albums/ah156/jdvorchak/84%20FJ1100/1C035CC2-DA4C-4CB0-ADA6-BF4CB87719C1_zpsqpyrpemp.jpg) (http://s1379.photobucket.com/user/jdvorchak/media/84%20FJ1100/1C035CC2-DA4C-4CB0-ADA6-BF4CB87719C1_zpsqpyrpemp.jpg.html)
Is that part of the wire retainer dangling out below the clutch basket?
Quote from: Troyskie on July 03, 2017, 02:42:07 AM
Quote from: jdvorchak on July 02, 2017, 01:38:37 PM
What the clutch assembly looks like
(http://i1379.photobucket.com/albums/ah156/jdvorchak/84%20FJ1100/1C035CC2-DA4C-4CB0-ADA6-BF4CB87719C1_zpsqpyrpemp.jpg) (http://s1379.photobucket.com/user/jdvorchak/media/84%20FJ1100/1C035CC2-DA4C-4CB0-ADA6-BF4CB87719C1_zpsqpyrpemp.jpg.html)
Is that part of the wire retainer dangling out below the clutch basket?
No. Actually that is part of the gasket that was dangling. The camera angle makes it look thin like a wire.
Quote from: red on July 02, 2017, 09:53:28 PM
If you want to get a welded repair on the crack, your best bet in to have a patch fully welded over the crack on the inside, to seal in the oil. The patch is welded onto clean, smooth metal then. On the outside, fill in the crack with welding material, then power-sand smoothly, for appearances. That is what an ace welder did for me, with excellent results.
I'm not a welder but I understand what you're saying. Welding a patch over the crack would be a challenge. The metal is actually pushed in from the outside so it sits very proud of the surface. If I tried to beat that back down level I'm sure it would just break off and result in a great big hole.
One of my sons is a pro welder and one is a body man. The body man came by and said he would take it to work. There is a custom racing motorcycle shop across the street that owes him a favor. If it can't be repaired I'll buy a new one now that some members have pointed out a couple of options.
Waiting for a battery and to get the clutch cover welded I decided to do a little aluminum polishing. I should have done some more "before" pics.
(http://i1379.photobucket.com/albums/ah156/jdvorchak/84%20FJ1100/CF91A4AB-AE40-45C3-82A7-56C380F76B46_zpsd4msq6uc.jpg) (http://s1379.photobucket.com/user/jdvorchak/media/84%20FJ1100/CF91A4AB-AE40-45C3-82A7-56C380F76B46_zpsd4msq6uc.jpg.html)
(http://i1379.photobucket.com/albums/ah156/jdvorchak/84%20FJ1100/74ad1260-43ce-404a-ad0f-f1cc0fd807fd_zpsp5joysqd.jpg) (http://s1379.photobucket.com/user/jdvorchak/media/84%20FJ1100/74ad1260-43ce-404a-ad0f-f1cc0fd807fd_zpsp5joysqd.jpg.html)
(http://i1379.photobucket.com/albums/ah156/jdvorchak/84%20FJ1100/490111B2-78A7-47AE-9E33-BB5401EE7A62_zpsgmknf32x.jpg) (http://s1379.photobucket.com/user/jdvorchak/media/84%20FJ1100/490111B2-78A7-47AE-9E33-BB5401EE7A62_zpsgmknf32x.jpg.html)
With polished aluminum, it seems like you're looking into the soul of the metal.
Nice work! :good:
Quote from: jdvorchak on July 06, 2017, 12:31:15 AM
Waiting for a battery and to get the clutch cover welded I decided to do a little aluminum polishing. I should have done some more "before" pics.
They look so Good, how did you get them so shiny?
Cheers Alan
Quote from: Sparky84 on July 06, 2017, 06:57:18 AM
Quote from: jdvorchak on July 06, 2017, 12:31:15 AM
Waiting for a battery and to get the clutch cover welded I decided to do a little aluminum polishing. I should have done some more "before" pics.
They look so Good, how did you get them so shiny?
Cheers Alan
I start with 500 grit wet/dry wet sanding until all of the pitting (dark spots) are gone. The part then has a uniform grey color. Then move to 1000 grit to remove the 500 grit scratches and finally 2000 grit to remove the 1000 grit scratches. Doesn't take as long as it sounds. Just a few minutes of sanding, probably 20 minutes total. Then I use aluminum, or they call it soft metal buffing compound, on a 5 inch buffing wheel attached to my grinder. Final step is to change buffing wheels and use Mothers Aluminum polish. That is the quick part. Only takes a minute or two with each pad/compound.
I'm often asked "How long do you sand and polish aluminum?" My stock answer is "Until you get tired of sanding and polishing". To get the parts looking like these, it really doesn't take long. To make them look like chrome? A lot, I mean a lot more sanding and polishing than I'm prepared to do. And quite frankly the soft aluminum alloy the Metric bikes used, back then, will never look like chrome. Except the fork lowers. I have polished parts on my Harley Davidon's to a chrome like finish. But that is such a PIA that I don't do it often.
(http://i1379.photobucket.com/albums/ah156/jdvorchak/08%20FXDL/8F462DBD-09AE-48DF-B3AC-8CBA08883583_zpsfmx6jogj.jpg) (http://s1379.photobucket.com/user/jdvorchak/media/08%20FXDL/8F462DBD-09AE-48DF-B3AC-8CBA08883583_zpsfmx6jogj.jpg.html)
(http://i1379.photobucket.com/albums/ah156/jdvorchak/08%20FXDL/D4D2058A-8450-4E2D-B3FA-662A49574960_zpszm9pqasg.jpg) (http://s1379.photobucket.com/user/jdvorchak/media/08%20FXDL/D4D2058A-8450-4E2D-B3FA-662A49574960_zpszm9pqasg.jpg.html)
FYI since I really can't match the semi gloss finish of the engine and covers, I got some high gloss engine paint and primer. I intend to paint the engine covers with the high gloss. Not OEM or stock looking, but a guy in the area has a Honda CB1100 with the side covers and valve covers painted high gloss and I really like the way that bike looks. It's an all black bike but they mixed semi gloss and high gloss.
(http://www.moto-net.com/sites/default/files/field/image/2014/Nouveautes/Honda/cb1100-2014-5.jpg)
I got the cover back from the welder, my son Jimmy. He said it was pretty easy to weld and was careful not to use too much heat.
(http://i1379.photobucket.com/albums/ah156/jdvorchak/84%20FJ1100/316244F7-B639-4D0E-AC21-8B279D5D41A4_zpsgzikuim2.jpg) (http://s1379.photobucket.com/user/jdvorchak/media/84%20FJ1100/316244F7-B639-4D0E-AC21-8B279D5D41A4_zpsgzikuim2.jpg.html)
(http://i1379.photobucket.com/albums/ah156/jdvorchak/84%20FJ1100/9950AB62-CD2B-4F05-B621-274FBFCD3D80_zpsz4txvye6.jpg) (http://s1379.photobucket.com/user/jdvorchak/media/84%20FJ1100/9950AB62-CD2B-4F05-B621-274FBFCD3D80_zpsz4txvye6.jpg.html)
And after some JB Weld applied. Now all I have to do is wait 24 hours for the JB to fully cure.
(http://i1379.photobucket.com/albums/ah156/jdvorchak/84%20FJ1100/40E762DC-64F6-4766-8F05-81C30070E679_zpstraumc9n.jpg) (http://s1379.photobucket.com/user/jdvorchak/media/84%20FJ1100/40E762DC-64F6-4766-8F05-81C30070E679_zpstraumc9n.jpg.html)
I applied JB Weld to the outside to insure no leaks and to build up the surface dent for sanding and final paint. JB Weld is good up to 550 Deg F so I'm sure it will hold up.