First test ride 84 FJ1100L

[jdvorchak]

Some of you may have seen my other topics about my 84 FJ1100 barn find. Well I overcame some minor problems and put it all together this afternoon. First test ride around the block and I noted a couple of things. One is after I get a couple of miles on it I'll sync the carbs. Bench sync only after rebuild.

The other just a little annoying problem is the clutch pull. It seems to engage the clutch as soon as you release the lever. I'd say within a 1/4 to maybe a 1/2 inch of lever movement. Way earlier than I'm used to.  Now I do have a broken bolt that holds the slave cylinder in so I'm hoping just that small amount of flex in the slave is what's causing the problem.

Third and this is most annoying to me. The fuel gauge doesn't come off E even with about 2 gallons of gas. The FUEL warning light came on about 1/2 way around the block. So something is working. So do you think I just don't have enough fuel in the tank to move the needle?Bike is still running with petcock on ON.

Comments please.

[fjbiker84]

Could the clutch lines be weak?  That may explain why the clutch engages too soon.  As for the gas gauge, it's working exactly as it was designed.... and was a complaint about the bike from the beginning.  My 84 hits the low fuel light even though there is around 2 gallons of fuel left in the tank. 

[TexasDave]

Could the clutch lines be weak?  That may explain why the clutch engages too soon.  As for the gas gauge, it's working exactly as it was designed.... and was a complaint about the bike from the beginning.  My 84 hits the low fuel light even though there is around 2 gallons of fuel left in the tank. 

Yes the fuel gauge is not very accurate on the 84's. Like most everyone on here I rely on the trip odometer.

Dave

[jdvorchak]

Could the clutch lines be weak?  That may explain why the clutch engages too soon.  As for the gas gauge, it's working exactly as it was designed.... and was a complaint about the bike from the beginning.  My 84 hits the low fuel light even though there is around 2 gallons of fuel left in the tank. 

The PO had changed all of the hydraulic lines over to braided SS lines... NICE!
I can see the slave cylinder actually flexing a bit when I pull the lever. Still have to call Randy and see if he has a m6x75 bolt for it.

thanks for the reply about 2 gallons left. Although all of the bikes I own have fuel gauges, except my 71 CL350, but I too rely on the trip odometer for accuracy.

[red]

The other just a little annoying problem is the clutch pull. It seems to engage the clutch as soon as you release the lever. I'd say within a 1/4 to maybe a 1/2 inch of lever movement. Way earlier than I'm used to.  Comments please.

jdvorchak,

There may be a brass bushing in the clutch handle, where the clutch master cylinder rod gets pushed.  Check that the bushing is not worn down inside, or worn through.  You can drop a tiny washer (or nut) into the bushing where the rod goes, for a temporary fix.

[Pat Conlon]

Hey Red, that was my first thought, then I remembered the early FJ's didn't have that bushing.
My second thought was air in the hydraulics causing a mushy lever.

[TexasDave]

Hey Red, that was my first thought, then I remembered the early FJ's didn't have that bushing.
My second thought was air in the hydraulics causing a mushy lever.

Without that bushing and the surface that presses on the rod are susceptible to a lot of wear. Might be time to pull and inspect that aluminum clutch lever.

Dave

[ribbert]

I can see the slave cylinder actually flexing a bit when I pull the lever. Still have to call Randy and see if he has a m6x75 bolt for it.

You just answered your own question. Given the ratio between the lever and the slave, a little bit of flex at the slave is going to be lot more at the lever.

Replace the missing bolt before something breaks, any nut and bolt shop will have one, other than being metric there is nothing special about it.

Noel

[jdvorchak]

All good suggestions and I'll check it out tomorrow. There does seem like a lot of "free play" in the clutch lever before I feel pressure. I had that lever off and I don't remember there being a lot of play on the pivot bushing.

[jdvorchak]

Not quite a normal bolt. It's an M6x75mm long! Discontinued by Yamaha. And being 75mm long it's not an Ace Hardware type item. There is a nation franchise near me call Fastenal and I should have gone and checked with them this past week. Shame on me. I'll check Monday.

Not all that worried about what I noticed on the test ride. I still have to replace the chain and sprockets, fix that broken bolt and do a tune up on the engine. Usually when I get a barn find I don't want to spend a penny more than necessary until I know it runs and rides. Well this one runs and rides!

[ribbert]

Not quite a normal bolt. It's an M6x75mm long! Discontinued by Yamaha. And being 75mm long it's not an Ace Hardware type item.

What I meant by "any nut & bolt shop" was just that, a dedicated nut & bolt shop, not a hardware shop. The shop you mention, if only by name, sounds as though they will have what you need.

Noel

[red]

Not quite a normal bolt. It's an M6x75mm long! Discontinued by Yamaha. And being 75mm long it's not an Ace Hardware type item.

What I meant by "any nut & bolt shop" was just that, a dedicated nut & bolt shop, not a hardware shop. The shop you mention, if only by name, sounds as though they will have what you need.
Noel

jdvorchak,

In the USA, the real Yellow Pages directory on the Internet is:

www.anywho.com

Click on the Yellow Pages tab, and put this into the heading line: Nuts & Bolts.  Put your ZIP code in the Location, and they will find every specialty shop under that heading near you.  You can set the list to sort by Distance.  Nuts & Bolts is a separate heading in the YP, not the same as Hardware.

[jdvorchak]

Thank you Red. That worked like a charm and I found 3 locations within 20 miles of me. Sounds like a nice little ride.

[jdvorchak]

One problem solved. The clutch lever was worn down to the point that you could see the imprint of the piston/plunger showing. Put about a 1/16 inch divot in the lever. In the interim I JB welded a washer onto the clutch lever just until a new lever is sourced.