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General Category => FJ Project Writeups => Topic started by: kirian on February 22, 2013, 04:18:14 AM

Title: FJ 1200 1tx ground-up rebuild
Post by: kirian on February 22, 2013, 04:18:14 AM
Hey!

As i said, i'm starting my project, after almost chopping my fj into a streetfighter, i decided to restore this beauty, and drive her as she diserves!

Here are the first pic's, i'll keep them coming as i move forward with the project.

First pic's, when i bought her, doesn't look much like an fj, does she?

(http://i35.photobucket.com/albums/d158/Kirian001/Yamaha/5280_1072269326587_1221758602_30171195_4768580_n.jpg)

(http://i35.photobucket.com/albums/d158/Kirian001/Yamaha/5280_1072269366588_1221758602_30171196_892131_n.jpg)

discovered that it was a cheap black spray, so i washed it down with some gasolene
(http://i35.photobucket.com/albums/d158/Kirian001/Yamaha/P1020121.jpg)

What i had planned, but dicided not to go down that road
(http://i35.photobucket.com/albums/d158/Kirian001/Yamaha/32189_1277865266357_1221758602_30628269_3998535_n.jpg)

(http://i35.photobucket.com/albums/d158/Kirian001/Yamaha/32189_1277865186355_1221758602_30628268_7467194_n.jpg)

More to follow...

Title: Re: FJ 1200 1tx ground-up rebuild
Post by: ribbert on February 22, 2013, 07:28:01 AM
Quote from: kirian on February 22, 2013, 04:18:14 AM

(http://i35.photobucket.com/albums/d158/Kirian001/Yamaha/32189_1277865186355_1221758602_30628268_7467194_n.jpg)


A garage with a pit. They used to be common but I haven't seen one for years.

You could park the bike right next to it and use it like a makeshift lift table.
Title: Re: FJ 1200 1tx ground-up rebuild
Post by: keand3 on February 22, 2013, 10:47:56 AM
Nice project you have going.. looking forward to more pictures  :good2:

Cheers
Ken
Title: Re: FJ 1200 1tx ground-up rebuild
Post by: FJ12PD on February 22, 2013, 12:54:35 PM
YOU could park your bike next to it with a fake coverover the hole, for a security system. Back on topic did it have a 900 ninja fairing on it?
Title: Re: FJ 1200 1tx ground-up rebuild
Post by: fj11.5 on February 22, 2013, 03:40:50 PM
have an awesome bike just waiting to be loved again  :biggrin:,, like the pit security idea, but needs a few pungy sticks in the bottom so the bastards cant just bugger off, ,
Title: Re: FJ 1200 1tx ground-up rebuild
Post by: kirian on February 26, 2013, 12:10:38 PM
Quote from: FJ12PD on February 22, 2013, 12:54:35 PM
YOU could park your bike next to it with a fake coverover the hole, for a security system. Back on topic did it have a 900 ninja fairing on it?

Yeah, that's the kawa gpz front fairing, someone mounted it up after a crash, i think, but, man, that's the ugliest thing i've seen in years... got rid of it as soon as i could. sold it
Title: Re: FJ 1200 1tx ground-up rebuild
Post by: kirian on March 24, 2013, 11:32:27 AM
I would not want you all to think i'm not doing anything. stripped the first one down... sorry for the poor pictures, cellphone cam

(http://i35.photobucket.com/albums/d158/Kirian001/WP_000174_zpse5f1030f.jpg)

(http://i35.photobucket.com/albums/d158/Kirian001/WP_000173_zps1f1b24d2.jpg)

(http://i35.photobucket.com/albums/d158/Kirian001/WP_000178_zps775d6bcc.jpg)

(http://i35.photobucket.com/albums/d158/Kirian001/WP_000177_zps60aa4996.jpg)

(http://i35.photobucket.com/albums/d158/Kirian001/WP_000198_zps019ea68e.jpg)

(http://i35.photobucket.com/albums/d158/Kirian001/WP_000199_zpsd03f0c3a.jpg)

also, tried out carbon vynil instead of a paintjob, i think it will look awesome, and save me some $$, i need both new tyres

(http://i35.photobucket.com/albums/d158/Kirian001/WP_000225_zps670ebdd5.jpg)

(http://i35.photobucket.com/albums/d158/Kirian001/WP_000226_zpsfef6bda1.jpg)

(http://i35.photobucket.com/albums/d158/Kirian001/WP_000228_zps915fadc3.jpg)

will update soon!!
Title: Re: FJ 1200 1tx ground-up rebuild
Post by: Steve_in_Florida on March 24, 2013, 11:36:53 AM

Your garage is WAY TOO CLEAN!

The vinyl idea looks like it might work. Good thinking!

Steve

Title: Re: FJ 1200 1tx ground-up rebuild
Post by: kirian on March 24, 2013, 11:43:56 AM
that was my "for car parking only garage :D

main garage is not useable : brothers intruder in bits and pieces, also rebuilding, and 2 more bikes parked newt to it, so i took my project to a clean place :D

Title: Re: FJ 1200 1tx ground-up rebuild
Post by: Thmsdoyle on March 24, 2013, 02:11:09 PM
The vinyl looks pretty good, how hard was it to work with? Is that the 3m 1080?
Title: Re: FJ 1200 1tx ground-up rebuild
Post by: kirian on March 25, 2013, 01:57:25 AM
it's actualy pretty easy. considering that was my first atempt at this, it's gone pretty well, and i'm statisfied. I think, that with some practice, i will not have any problems.

No, it's not 3m, it's tr1 (some chinese brand), but does the job well :D , cost me 20$ for 1.2 square meter, and i think i will need 2.5 more, so, in total, all the paintjob ill be 60$, and that is far less cheaper than 300-400$, that i would pay in a garage to paint it, and did not want to do it myself.
Title: Re: FJ 1200 1tx ground-up rebuild
Post by: kirian on April 11, 2013, 02:16:48 AM
moving on with my project... slow but getting there. FYI, all the fairing mounts are repositioned on the 3cv, not the same as 1tx, so that's one job i did not plan to do...

had to cut new brackets from 3cv frame and weld them to my 1tx... btw, someone mentioned that my garage is way too clean, so i moved to my friends garage, he has far more tools, and with an extra set of hands i'm thinking this project will be going much quicker.

there, he donor motor and the old frame :D
(http://i35.photobucket.com/albums/d158/Kirian001/WP_000246_zpsb6ea7779.jpg)

grinding old 1tx mounts
(http://i35.photobucket.com/albums/d158/Kirian001/WP_000247_zpscbc35778.jpg)

(http://i35.photobucket.com/albums/d158/Kirian001/WP_000248_zpsc566d1ec.jpg)

wellding new mounts
(http://i35.photobucket.com/albums/d158/Kirian001/WP_000255_zpsa130c950.jpg)

testing the fairing, and, it fits like a glove :D
(http://i35.photobucket.com/albums/d158/Kirian001/WP_000252_zps0545764e.jpg)

more to folow soon
Title: Re: FJ 1200 1tx ground-up rebuild
Post by: Catlin987987 on April 11, 2013, 07:21:13 PM
Quote from: kirian on February 22, 2013, 04:18:14 AM

(http://i35.photobucket.com/albums/d158/Kirian001/Yamaha/5280_1072269326587_1221758602_30171195_4768580_n.jpg)


Is that just a cut front fairing?
Title: Re: FJ 1200 1tx ground-up rebuild
Post by: kirian on April 16, 2013, 05:19:49 AM
no that was a kawasaki ninja (gpz900) fairing. got rid of that
Title: Re: FJ 1200 1tx ground-up rebuild
Post by: Papa Weeley on May 15, 2013, 12:00:36 PM
Updates?   :smile:
Title: Re: FJ 1200 1tx ground-up rebuild
Post by: kirian on May 20, 2013, 01:46:47 AM
in a bit of a drag here, the frame is prepped for painting (gloss black), so the project is at a standstill. heading today to the bodyshop to sand it all and clean it, maybe spray it today, so i can start the assembly. pics to folow when frame arrives from the bodyshop.

Cheers m8s
Title: Re: FJ 1200 1tx ground-up rebuild - finishing the metalwork (01.06.)
Post by: kirian on June 03, 2013, 04:22:44 AM
So, last week, i recieved my frame, gloss black, very nice. since the weather here is awfull, and rainy, my mate and i decided we'd use friday and saturday to dissasemble donor bike and start building the black one. luckily, things got out of sontrol, and from 17:00 untill 02:00 the bike was finished on friday, and we started her up. here are a few pictures with modest descriptions. all the parts were inspected, and cleaned and lubed if needed.


frame, fresh from the oven :D
(http://i35.photobucket.com/albums/d158/Kirian001/Yamaha/WP_000260_zps8f6c2e6b.jpg)

in the back, the donor frame, we dissasembled the whole bike in 3 hours
(http://i35.photobucket.com/albums/d158/Kirian001/Yamaha/WP_000259_zps2ec56ac5.jpg)

(http://i35.photobucket.com/albums/d158/Kirian001/Yamaha/WP_000261_zpsb06be794.jpg)

the heart, familiar to all... ready to be washed.
(http://i35.photobucket.com/albums/d158/Kirian001/Yamaha/WP_000262_zps2900ce20.jpg)

u can see through the door, it's still daylight (around 20:00)
(http://i35.photobucket.com/albums/d158/Kirian001/Yamaha/WP_000263_zps45a2f380.jpg)
assembly started
(http://i35.photobucket.com/albums/d158/Kirian001/Yamaha/WP_000265_zps8f419760.jpg)

(http://i35.photobucket.com/albums/d158/Kirian001/Yamaha/WP_000266_zpsdbfcce47.jpg)

rear fork in position
(http://i35.photobucket.com/albums/d158/Kirian001/Yamaha/WP_000267_zps41ce2664.jpg)

front fork in position
(http://i35.photobucket.com/albums/d158/Kirian001/Yamaha/WP_000268_zps1fbddeb0.jpg)

(http://i35.photobucket.com/albums/d158/Kirian001/Yamaha/WP_000269_zps6376182a.jpg)

tailframe in place
(http://i35.photobucket.com/albums/d158/Kirian001/Yamaha/WP_000270_zpsa761c6cc.jpg)

friday over, she is running, so let's go to sleep (02:00)
(http://i35.photobucket.com/albums/d158/Kirian001/Yamaha/WP_000271_zpse8b58d5a.jpg)


on saturday, we tried on the fairings, changed the clutch and brake oil, left her running, was dead-cold for 3 months.
(http://i35.photobucket.com/albums/d158/Kirian001/Yamaha/WP_000274_zpsf7d8055d.jpg)

(http://i35.photobucket.com/albums/d158/Kirian001/Yamaha/WP_000275_zps881fd2ad.jpg)

parked, go back to sleep baby...
(http://i35.photobucket.com/albums/d158/Kirian001/Yamaha/WP_000276_zpsd1181f93.jpg)

now waiting for the fairings to be painted, si i can finish her.

Title: Re: FJ 1200 1tx ground-up rebuild
Post by: The General on June 03, 2013, 06:41:17 AM
Well done!  :good2:
Ummm...Croatia ay...If you can make it to my place just before our Snowy rally...I might have a little job for ya!...I`ll even find a spare bike for you to ride in the Rally.  :drinks:
Title: Re: FJ 1200 1tx ground-up rebuild
Post by: Steve_in_Florida on June 03, 2013, 07:48:12 AM

Your project looks really good!

I like the way they come apart and go together so quickly, kind of like a 1:1 scale model.

Steve

Title: Re: FJ 1200 1tx ground-up rebuild
Post by: racerman_27410 on June 03, 2013, 04:17:43 PM
  getting there....:good2:


KOokaloo!


Frank


Title: Re: FJ 1200 1tx ground-up rebuild
Post by: squidley63 on June 04, 2013, 05:51:17 AM
Really cool project and I love the black frame. Best part of these projects though is hanging out with our buddies while working on them and getting to tell the remember that time we were working on your bike and went from bare frame to running overnight stories years later.
Title: Re: FJ 1200 1tx ground-up rebuild
Post by: kirian on June 04, 2013, 05:03:33 PM
yea, it was really fun. we do a lot of similar projects, but mostly cars, bikes not, only my bike.

anyways, the bike is as is, have to get the fairings prepped for paint (they were broken so the plastic needs to be welded together), and paint it. it will be dark blue, as is the tank and the sidefairings. also, i have to redo my front forks, rode the bike yesterday down the street, feels really weird, it's either the tire, or the forks, or the combination. the cheapest fix is to change fork oil and seals, and we'll go from there. that's the project for this weekend.

also, fell in mide to swap my exhaust for this (z1000 phase1 stock), what do you all think?

(http://image.sportrider.com/f/8598104/146_03_21zoom+2003_kawasaki_z1000+exhaust.jpg)

Title: Re: FJ 1200 1tx ground-up rebuild
Post by: racerman_27410 on June 04, 2013, 08:50:13 PM
i dont think you;re going to be happy with the way those kawi pipes sound.


KOokaloo!
Title: Re: FJ 1200 1tx ground-up rebuild
Post by: fj11.5 on June 05, 2013, 02:13:00 AM
Often thought about fitting a twin outlet system instead of my 4/1 , but love the sound of the 2 1/2" carbon pipe