1986 FJ1200 Project

[dadofseven38]

Bought this from a deployed friend, 250$.  It turns over but wont start.  Sent the carbs to RPM, bought new fuel sending unit from Ebay, got a new Petcock and throttle cables from RPM, getting the tank re-sealed locally, when I get that all back together we will see if it starts.  After talking to Robert at RPM, these engines are pretty solid, only 37k miles on the bike. The paint job is not to bad, just some light scuffs here and there, looks to be a pretty decent job.  If it starts I will break it further down, get the oil and plugs changed out, then take a look at the clutch and get to scrubbin.

Going with a Delkavic 4 into 2 oval exhaust, then just new tires and it should be ready to run around a bit.  Long range is to get the front and rear suspensions updated to 17" tires, better tire selected with that route....92 FZ1000 front ends are a bit scarce, but I will track one down.
Any other ideas folks have, just chime in.

Can't say enough about RPM, those guys have made this project so much easier, prices are pretty decent, and if they don't have it, they know someone that does.

Jim

[Millietant]

Sounds like you've got a list of sensible mods there "Dad". I've got the FZR USD front end, with FZ1 blue spot calipers and master cylinder and a YZF 600 R Thundercat 17"x5" rear wheel (bought the complete unit). Both fitted very easily with very minor works (a small "bracket" to provide lock stops for the front forks, 2002 FZ1 handlebar risers and handlebars), a mixture of FJ (wheel, spindle etc, sprocket, caliper, torque arm) & YZF (wheel, disc, caliper mount bracket) parts and a tiny bit of machining. This gave me access to great 17" tyres ont and rear.

All of this, with a new higher spec rear shock and slightly heavier fork springs, handling and braking are a world apart from original. You will be happy when it's all done 

[Millietant]

Unfortunately, there seem to be a few '91-'95 USD FZR 1000 forks, wheels and triple trees available on eBay in the UK, but nothing I can see from the USA.

[dadofseven38]

Gas tank is done!! Carbs should be in this week as well.

[dadofseven38]

Carbs are in, new petcock is in, sending unit is on the bench...... waiting for the sending unit gasket, then we will see if this things wants to run....

[dadofseven38]

Its alive!!!

https://youtu.be/aai91BUN4sM

[dadofseven38]

Replaced the crappy aftermarket rear turn signals with a set of OEM from Ebay that I had to clean up just a bit, and started painting some of the areas I could get to, engine cases, front sprocket cover.  The kickstand area was badly corroded from the battery box, so I got that to.

[Millietant]

You just can't leave it with the cylinder head fin edges still black.....polish them...pleaseeee   

[moparman70]

I agree -- I have one with that all black look and maybe its because I am used to seeing the sides more over the years but I don't like the look.  The other one I made sure I removed the sides after painting --- but to each person their own.


PS --looks like great progress -- I can't tell from the pictures but make sure you have the heat shield that sits underneath the gas tank --

[dadofseven38]

I tried using a small file, and it took to much metal off, I will use a small dremel wheel and see what happens....I kinda like to blacked out look....we shall see....

[dadofseven38]

Front suspension off, and headed to RPM....and....sanded of the engine black from the cooling fins....

[dadofseven38]

Generic Knock Off can, checking for fitting, spacer added so the can clears the suspension, swingarm and passenger peg, bike is on the center stand so the swingarm will be a bit higher as well. Next is the mid pipe bend at a local muffler shop....thoughts??

[dadofseven38]

Generic Knock Off can, checking for fitting, spacer added so the can clears the suspension, swingarm and passenger peg, bike is on the center stand so the swingarm will be a bit higher as well. Next is the mid pipe bend at a local muffler shop....thoughts??

Can and midpipe done!  Need to paint the collector and clean up some of the welds, but it worked great, and sounds amazing.  Suspension front and rear done, next is a thorough cleaning and shining up.  Then plastics.