Yes, New York...the Bronx to be exact.
A while back an FJ owner called inquiring about working on his 1991 FJ1200. He had purchased it brand new. It had not run a quite some time and he was unable to find a local shop or mechanic to get it running for him. I assured him we could handle anything he needed for his FJ.
On one of the final calls, he asked, "What is the best way to get there from New York?"....and then the obligatory repeat question back to him; New York...?
Well, just get on I-80 west and head for California. Once you hit Highway 99 head south and then Highway 120 to Oakdale was the answer back to him.
He said, "We are leaving on Friday and should see you guys on Monday or Tuesday".
Monday and Tuesday went by, no word. We thought well that didn't pan out. But then on Wednesday mid-morning the phone rings, the caller says; "We are in Wells, Nevada and are hoping to be there before you close for the day." Knowing where he is on the road, I know we'd see them in the morning.
Thursday morning a maroon Ford pick-up pulls up in the front of the shop, a U-Haul trailer behind with a 91 FJ1200 in it. The license plates on the truck say "New York". The plate on the FJ say "New York". Holy smokes...he really drove out all the way from New York for us to work on his FJ.
Lar's the owner says, "We got stuck in the snow for two days in Wyoming or we would have been here as planned".
The bike gets unloaded. The goal before making anymore decisions is, "Will it run".
It has been to so many shops/mechanics and they can't get it running. He doesn't want to spend a bunch of money upgrading if there is something mechanically wrong internally in the engine.
I about twenty minutes after rolling it off the trailer, we pop on a set of carbs from a race car we are working on. Install his new battery and hit the button.
It cranks around about three times and fires right up. I immediately notice how mechanically quiet the engine is. There is no smoking and this appears to be a real cream puff internally. I look at the odometer and it reads 3930...yes, three thousand nine hundred and thirty miles. This thing is still brand new, but it has been raped by unqualified people working on it.
So, Lar's is happy to hear it run, so out come the pen & paper for the work he wants done. He has brought R1 front & rear suspension to be installed are the major items.
We have the list made and the work is beginning. I will post up as the build proceeds.
Lar's left his FJ and headed back to New York on Friday. They made it home early this week.
We started working on it yesterday afternoon and are down to the blank canvas to build her back up.
He wants to fly out in the spring when the bike is done and ride it. From there he will probably have it shipped back. I have not discussed with Lar's yet, but I am kind of hoping to have his trip back out in the spring occur so he can attend the 2018 WCR.
Much more to come.
Randy - RPM
What a beauty!
I will follow this thread with great excitement.
Yeppers, I'm in.... Did Lars have all the components needed for the R-1 conversion?
Wow! 3930 miles. Another FJ resurrected!
Quote from: Pat Conlon on November 16, 2017, 11:58:41 AM
Did Lars have all the components needed for the R-1 conversion?
All the big, heavy listing is all done.
Fork extensions, rear shock, GPS speedo as well as all of the little details still need to be sorted; but the ball is already rolling.
Frame and engine are ready for soda blasting and repainting to start the project.
Randy - RPM
What a love Lars has for his FJ. :i_am_so_happy:
Awesome!
Quote from: fjbiker84 on November 16, 2017, 12:02:34 PM
Wow! 3930 miles. Another FJ resurrected!
A true 3900 mile bike.
There is minimal build up of chain goo on the frame.
And for the very first time, I did not have to press out the front motor mounts, they slid right out.
Randy - RPM
The fact that he would drive all the way from New York to deliver it to RPM should say it all about the level of service and workmanship that RPM has to offer for all of us FJ owners. We are all lucky to have a source of parts and expert help to keep our old bikes on the road. Thank you Randy and your family.
Most interesting
I now know just what I want for Christmas!
Thank you for posting, as I'll be very interested in the progress, also.
Steve
Another story of greatness begins. The Fj mojo is strong in this latest project. Proof once again that the brightest spot in the universe probably has Yamaha stamped on it.
What a project to take on, fantastic! I know this bike will be better than showroom when it is finished,
Randy,
are you painting or powder-coating the frame? I ask because I've always wanted to power-coat but the local PC shop is very skeptical that the Federal emissions tag under the steering stem will survive the heat. And as you know, the DMV takes a very dim view of bikes without that tag.
So I assume you're masking and painting, yes? Or do you have some magical way of preserving the tag while powder-coating?
Bill
It will be sand blasted and painted. There is too much rust on the frame too not address.
Received the frame back from the media blaster today, all nice & clean.
No more rust :yahoo:
Waiting on the color selection from the owner before getting it painted next week.
Randy - RPM
(popcorn)
We all know the FJ should have left the factory with a black frame. Oh yeah and a fork brace.
Quote from: andyoutandabout on December 01, 2017, 09:16:36 PM
We all know the FJ should have left the factory with a black frame. Oh yeah and a fork brace.
:good2:
Quote from: TexasDave on December 05, 2017, 10:31:33 PM
Quote from: fj1289 on December 05, 2017, 09:35:37 PM
Quote from: andyoutandabout on December 01, 2017, 09:16:36 PM
We all know the FJ should have left the factory with a black frame. Oh yeah and a fork brace.
:good2:
:negative:
I'm with Dave. Yamaha did a fine job with the OEM colors on our FJ's (especially the '84's)
Yamaha created a timeless classic that outlives all fads......like black frames.
Did the blasting shop mask off the federal ID sticker under the neck?
Quote from: Pat Conlon on December 06, 2017, 02:31:05 AM
I'm with Dave. Yamaha did a fine job with the OEM colors on our FJs.
Yamaha created a timeless classic that outlives all fads......like black frames.
Yes, they did, even when the color black was chosen for their subframes too. However, the durability, or longevity of its color of their frame's paint isn't all that good. But that can be expected of a bike of its era and its decades of use.
Whatever coatings and methods of prep and application that some OEMs are using for their frames, regardless of color choice, offer much more in appearance and durability than the old FJ paint.
Quote from: CutterBill on December 06, 2017, 06:04:20 AM
Did the blasting shop mask off the federal ID sticker under the neck?
No, I did before I took it there.
That sticker is not a necessity because it is a sticker and subject to damage. The stamping of the VIN in the frame if the mandatory requirement for the motorcycle registration.
I wanted to keep the sticker on this bike because it is not my bike. I don't want to create any issue for Lars in NY having registration issues. If it was mine, it would have been gone.
Randy - RPM
Hmmm, interesting....
Just an FYI, I bought 2 FJ's last year from a fellow near Seattle (both registered in Washington) and had them delivered to my house here in California. I rode the first bike to the closest DMV. The first thing the inspector wanted to see was that federal ID sticker under the neck. He said without it, I could not register the bike in CA. (The sticker was there and the registration proceeded without any problems.)
A few days later I trailered the non-running second FJ to a different DMV (closer to work) where the inspector there told me the very same thing. Only she was not allowed to climb up on the trailer to see it; said I had to unload the bike so that she could check for the sticker. Ever unload and then reload a non-running FJ by yourself? Oof, that was a workout. Anyway, the sticker was there and I got the bike registered.
That was my experience. YMMV...
Bill
The ID sticker subject is quite interesting. Having just jumped through hoops recently to get my Grey Import registered here in Kansas. The inspector told me he did not need too look at the sticker. He said "Stickers are easily forged and changed. He needed to look at stamped VIN on the frame and engine.
Fred
Quote from: Pat Conlon on December 06, 2017, 02:31:05 AM
Quote from: TexasDave on December 05, 2017, 10:31:33 PM
Quote from: fj1289 on December 05, 2017, 09:35:37 PM
Quote from: andyoutandabout on December 01, 2017, 09:16:36 PM
We all know the FJ should have left the factory with a black frame. Oh yeah and a fork brace.
:good2:
:negative:
I'm with Dave. Yamaha did a fine job with the OEM colors on our FJ's (especially the '84's)
Yamaha created a timeless classic that outlives all fads......like black frames.
The 84 paint scheme looks awesome with a black frame!
I'm in search of a 91+ fairing subframe for this bike.
http://www.fjowners.com/index.php?topic=17475.0 (http://www.fjowners.com/index.php?topic=17475.0)
If you know of a good straight one, please let me know.
Randy - RPM
Curious, how did such a low mileage bike tweek the subframe?
Must be the rats...
Quote from: racerrad8 on December 07, 2017, 10:39:50 AM
I'm in search of a 91+ fairing subframe for this bike.
http://www.fjowners.com/index.php?topic=17475.0 (http://www.fjowners.com/index.php?topic=17475.0)
If you know of a good straight one, please let me know.
Randy - RPM
About the only one that looks that I can find is in Germany. https://m.ebay.com/itm/E2-Yamaha-FJ-1200-3cy-3YA-ABS-Fairing-Support-Bracket-Fairing-Front-Frame-Front/401408849861?hash=item5d75d4f7c5:g:0KoAAOSw8cNUPn1S (https://m.ebay.com/itm/E2-Yamaha-FJ-1200-3cy-3YA-ABS-Fairing-Support-Bracket-Fairing-Front-Frame-Front/401408849861?hash=item5d75d4f7c5:g:0KoAAOSw8cNUPn1S)
Have you checked with Bob Weymouth? There is a good chance he may have one.
Fre
Quote from: Pat Conlon on December 07, 2017, 12:20:28 PM
Curious, how did such a low mileage bike tweek the subframe?
It got dumped by a mechanic test riding it right in front of him. The left mirror was basically pointing straight up when it arrived. The fairing is all broken up too...
Quote from: aviationfred on December 07, 2017, 12:49:59 PM
Have you checked with Bob Weymouth? There is a good chance he may have one.
Yes, I have an email into Bob; waiting to hear back from him.
Randy - RPM
I don't know if you would be able to talk this guy into shipping this. It would cost a big chunk, but it is advertised as new.
https://m.ebay.com/itm/FJ1200-fairing-front-new/162260104130?hash=item25c774b3c2:g:i34AAOSwA3dYFAIt
Fred
If only we could buy new fairings for $325. Sigh...
Got the frame sprayed with primer today.
That will prevent the rust from forming on the bare steel after having it blasted.
The next thing to get blasted is going to be the engine. The salted roads sure do a number of the aluminum and everything else.
We are not used to this type of corrosion in California.
Will hopefully be getting started on all of the required machine work after the first of the year.
Randy - RPM
Wow, the pictures do not look like less than 4K on the clock.
Biking through the Brit winters of the 80s made your ride look like it had been left on the sea floor for a century. Fortunately they don't salt anymore, using some other medium these days I believe.
I'm amazed how little rust is on our 12 year old truck as well.
Thanks California.
How much would it cost for shipping back to his place? (Maybe we could do a deal). :biggrin:
Well of course, I will be tuned in to this thread to see how the FJR1 mod comes out!! I think I know!!
Randy - just sent you email with the Penske shock details and some good contact info.
:good2:
tim
PS: Black frame = yes please!!
Quote from: racerrad8 on December 07, 2017, 01:37:39 PM
Quote from: Pat Conlon on December 07, 2017, 12:20:28 PM
Curious, how did such a low mileage bike tweek the subframe?
It got dumped by a mechanic test riding it right in front of him. The left mirror was basically pointing straight up when it arrived. The fairing is all broken up too...
Quote from: aviationfred on December 07, 2017, 12:49:59 PM
Have you checked with Bob Weymouth? There is a good chance he may have one.
Yes, I have an email into Bob; waiting to hear back from him.
Randy - RPM
https://www.ebay.com/itm/1990-FJ1200-COWL-STAY-FAIRING-BRACKET-YAMAHA-FJ-1200-1989-90-3SK-28359-00-00-/172796639847?vxp=mtr&hash=item283b7b7a67 (https://www.ebay.com/itm/1990-FJ1200-COWL-STAY-FAIRING-BRACKET-YAMAHA-FJ-1200-1989-90-3SK-28359-00-00-/172796639847?vxp=mtr&hash=item283b7b7a67)
Don't know if this is what you are looking for.
Dave
Quote from: TexasDave on December 08, 2017, 02:18:11 PM
https://www.ebay.com/itm/1990-FJ1200-COWL-STAY-FAIRING-BRACKET-YAMAHA-FJ-1200-1989-90-3SK-28359-00-00-/172796639847?vxp=mtr&hash=item283b7b7a67 (https://www.ebay.com/itm/1990-FJ1200-COWL-STAY-FAIRING-BRACKET-YAMAHA-FJ-1200-1989-90-3SK-28359-00-00-/172796639847?vxp=mtr&hash=item283b7b7a67)
Don't know if this is what you are looking for.
Dave
Dave,
That one will not work. The 91+ went to the odd shape headlight. That stay will only fit the square headlight models of 89-90.
Thanks for the thought.
Randy - RPM
Why ship it? Fly in and ride it back. Hope he makes the Rally.
bump for update...
Still gathering parts and working on the machine work.
Nothing to really update lately.
Randy - RPM
Dropped the engine off today for soda blasting. Once it is all cleaned up, it will get a fresh paint job.
Randy - RPM
I received some photos from the machinist yesterday with a few of the parts he is making for me.
We decided to go a different way to fit the FJ stem into the R1 lower triple. I welded the bottom of the stem up to add material both for the larger diameter and length.
Since we are not using the factory snap ring as it falls right at the line where the additional length needed to be started, we added a step shoulder at the bottom. The upper hat can also be seen on the stem.
The swing arm was machined off each side. He then machined the outside diameter to ensure the seal/cups/washers fit without issue
I will have everything back from him next week so I can start mocking everything up.
The engine is also back from soda blasting. I have those photos on a different computer and will post them up later. We have put the first coat of paint on the engine as well.
Randy - RPM
That's looking really good Randy. Have you done the swing arm pivot yet? its exciting to see another FJ going the R1 route!
T
Quote from: axiom-r on March 12, 2018, 03:01:15 PM
That's looking really good Randy. Have you done the swing arm pivot yet? its exciting to see another FJ going the R1 route!
T
Yes, but I went a different way. I am awaiting those parts and hope they get here this week.
Stay tuned.
Randy - RPM
Beautiful work on that steering stem! :good2:
On the swing arm pivot, I went with a way that I thought was less work for fitment. When Tim did his, he cut the inner R1 bearing spacer to length and then had internal bushings made to reduce the internal size for the FJ swing arm bolt. The problem with that I believe is the difficulty keeping the bearing surfaces perfectly aligned during the welding.
I had bushings machined to fit the stock FJ swing arm bearings into the swing arm. That way I did not have to cut, hold precisely the R1 swing arm inner bearing race while welding.
So, with the removal of the material from the outside edges of the R1 swing arm to match the overall width of the FJ swing arm, the only other modification required was the fabrication of the bushings for the FJ inner bearing spacer in the R1 swing arm.
We should be having some mock up time of the next couple of weeks to see how it worked out.
Randy - RPM
Just thought I'd bump this thread back to the top - seems like no news for 5 months !
Separately Randy - what paint did you use on the engine - I'm repainting mine but am not sure which is the best to use ....too many options for me to just pick one without some feedback.
Cheers.
Quote from: Millietant on August 03, 2018, 02:56:41 PM
Just thought I'd bump this thread back to the top - seems like no news for 5 months !
Separately Randy - what paint did you use on the engine - I'm repainting mine but am not sure which is the best to use ....too many options for me to just pick one without some feedback.
Cheers.
Yeah, once spring hits business picks up and major projects have to get put on the back burner. We have made a few small progressions, but I have not photographed anything to write it up yet. We have the steering lock finally sorted out I believe...that has been one step forward and two steps back. Now we have to start on getting the steering stops modified.
Once that is complete, I think we will be ready to paint on the frame and the final coat of paint on the engine.
For the engine paint we use,
PJ1 Gloss Black Engine & Case Paint (http://www.rpmracingca.com/proddetail.asp?prod=PJ1GlossBlack).
There will be more updates as we start getting int the fall months when the racing and riding seasons stop for the winter.
Randy - RPM
Thanks Randy, that's great.
I'm in the middle of giving my '89 3CV a bit of a middle-age spruce up. Hopefully it'll be ready before the good weather breaks.
Cheers.
(popcorn)
Quote from: Troyskie on August 19, 2018, 02:06:31 AM
(popcorn)
Sorry Troyskie...nothing new since this post earlier this month.
My dad did shoot down my thoughts on the steering lock modification, but that is how I learn :good2:
Quote from: racerrad8 on August 04, 2018, 12:07:43 PM
Yeah, once spring hits business picks up and major projects have to get put on the back burner. We have made a few small progressions, but I have not photographed anything to write it up yet. We have the steering lock finally sorted out I believe...that has been one step forward and two steps back. Now we have to start on getting the steering stops modified.
Randy - RPM
:good:
This was a good thread to read while there were updates. Amazing the corrosion that occurred with only about 3k miles. I was thinking about whether it would be safe to blast an engine without any media incursion into the vital areas. Apparently it is possible. I like the exhaust caps you guys use. What about the intake side? I'm guessing vacuum caps for the various hoses/vents? Now if customers would only stop sending in their carburetors and ordering parts, Randy would have time to finish this project. :sarcastic: But, that's a good problem for a business to have.
Quote from: Tuned forks on September 22, 2018, 01:37:08 PM
This was a good thread to read while there were updates. Amazing the corrosion that occurred with only about 3k miles. I was thinking about whether it would be safe to blast an engine without any media incursion into the vital areas. Apparently it is possible. I like the exhaust caps you guys use. What about the intake side? I'm guessing vacuum caps for the various hoses/vents? Now if customers would only stop sending in their carburetors and ordering parts, Randy would have time to finish this project. :sarcastic: But, that's a good problem for a business to have.
You'll get to see it in person in a couple of weeks...
Once we get past the RPM Fall rally we seem to drop right into the colder weather and the riding season winds down quickly.
Progress will again start shortly.
Randy - RPM
Got some fairing work done yesterday. Fabbed up some new tabs using PlastiFix. Thanks to Rick who was telling us about it at one of our get togethers and whoever else has used this stuff. It is amazing. Completely fabricated new tabs and after it hardened you would be hard pressed to break them off without trying to purposefully or dropping the bike.
Isn't it great stuff? I still have no cracks in my fender tabs.
Damn Robert, that's a lot of plastic repair for a machine with just 3k miles.
Rick, where is it sold locally or is it an online purchase?
Joe
Quote from: Tuned forks on November 27, 2018, 09:50:33 PM
Damn Robert, that's a lot of plastic repair for a machine with just 3k miles.
Rick, where is it sold locally or is it an online purchase?
Joe
I think I got it off Amazon
Amazon Link (https://www.amazon.com/Urethane-Supply-PlastiFix-Kit-Clear/dp/B0007LTXVY/ref=sr_1_1?ie=UTF8&qid=1543414403&sr=8-1&keywords=plastifix)
(https://images-na.ssl-images-amazon.com/images/I/81IeyXscOxL._SL1500_.jpg)
Quote from: Tuned forks on November 27, 2018, 09:50:33 PM
Damn Robert, that's a lot of plastic repair for a machine with just 3k miles.
I do not recall the whole story. But it was something like the bike got dropped off and the mechanic wanted to take it for a test ride. I think he said it was on the ground before he left the parking lot.
The carbs were destroyed as well, I don't know if it was the same mechanic or not but they busted off ALL of the float pin towers inside the carb body. That was one of the reasons for such a long haul trip. He had, had the bike to several different places and none of them could get it running and some of them wouldn't even touch it to begin with. I told him we could get it running, most likely in about 30 minutes, if the bike was running when he parked it and the tank was clean it was most likely carbs; unless one of the other mechanics did some crazy diagnosis and opened the motor up for some reason but with so little miles on her, I was pretty confident.
The first thing we did when he got here was put her up on the lift took a set of carbs of one of our bikes and installed on his bike, hooked up a fresh battery, and she started right up. At that point he said that he knew he had made the right choice.
....and then the mods began...
Bwhahahaha
Yea, basically, at that point we told him we could put a new set of carbs on it, the new battery, some fresh oil, and new tires and he could head home. BUUUUUUUTTTTTTTTTTTTTT he said he wanted the USD so he could get the chicks. And now here we are.
Yes indeed...however...He has to have the bike back before he gets the chicks.... :good:
The USD's are the easy part (nice solution on the stem).....figuring out the shock and linkage on the R1 swinger is the hard part.
Take lot's of pictures Robert. It's a cool project.
BTW, reminds me, check with your dad when you get a chance, he mentioned something about getting some custom steering stems made that would help us with the YZF USD conversions (instead of having to weld the FJ stem, then machine down the diameter to fit the YZF lower tree)
Cheers laddie, stay warm!
Good to read about this project again. I hope he has another motorcycle to ride while the FJ is in RPM jail.
Quote from: Pat Conlon on November 28, 2018, 11:27:55 AM
Cheers laddie, stay warm!
Yeah, no kidding Pat. Unless Robert has a heater it's probably colder than a well digger's a$$ in that shop.
Joe
It has been a while since we have made any progress on the FJR1.
But work has been slowly progressing. The shock has finally been worked through. The shock that Tim purchased is no longer available. So, after getting shock bodies, shafts and springs we were finally able to work to a finished product. Unfortunately, the upper shock mount has to be modified to clean the attached reservoir. So, we are working through that now for the final set up.
The R1 Linkage looks like it might be right in the acceptable range. If not, we will make adjustments at the relay triangle. I am going to stay away from the single shear design Tim had fail on him. I was able to press out the origninal bearing at the front of the arm. I then machined it to fit the FJ bearing so I could use the FJ inner race from the factory relay arm.
The front end is complete as far as mock up is concerned. The key locks the steering head and the steering stops has been modified to ensure the clip-ons don't hit the fairing.
So, once we get this final fitment of the shock & linkage sorted out, it is time to strip it back down for paint on the frame. The engine is painted and ready to install. From them it is the detail work of reassembly, but this is the time things really start moving along.
I think the posts will be more frequent as we are started on the downhill roll.
Randy - RPM
Looking really nice Randy!
Would you let us know what shock body, shaft and spring weight you ended up with? Length center to center? How much ride height adjustment is available etc... I am particularly interested in the spring weight and the triangle linkage configuration. I ended up inverting the stock triangle for a near perfect fit - although no clue what that did to the progressive rate... I see you got the torrington bearing in there!
When I was mocking up the shock and the remote res clearance issue emerged, I thought about a billet extension block that would mount in the FJ frame and then present a mount for the shock that was an inch or so to the rear. This would stand the shock more vertically and again impact the progressive rate linkage. As I recall, the folks at Penske indicated this would be a positive change to help reduce the required spring rate. The more important outcome to me was that the frame would go uncut at the shock mount. We went with the remote reservoir clip instead to avoid frame contact at the mount.
Nice work on the billet R1 dogbone!
Would love to see the front end and the triple clamp you went with as well as the mods to the steering stop - all critical steps in making the FJR1 happen...
Cannot wait to see this bike on its new wheels!
Cheers!
tim