1992 FJ12 Project/Resto

[Troyskie]

Nice big project Ray! Looks like it will be a good education for newbs like me.

[X-Ray]

Wow, where has the last 3 months gone?? Haven't progressed all that far, but the carbs have been finished, and this weekend got the bike ready to start for the first time since I got it from Doug. The old black oil was drained, new filter and oil went in, and the carbs were remounted. Glad I had my bike at the ready for reference, leave things too long and some things get forgotten. Man, aren't those throttle cables a joy to get back on, flamin heck!

Back to the carbs, so far the liquid electrical tape trick for holes and tears in the diaphrams seems to be working. It seems to become part of the rubber itself and is pretty hard to scratch off. One of the photos shows what I had to do to get the new emulsion tubes back into the bodies, which certainly did not go in as easily as the old ones came out. They were a very tight fit and actually required some solid taps with a hammer to drive home, lining up the locating lug as it went in. Glad these won't have to come out again for a long time. The first day I had the carbs back on and started the bike, (with the battery and Unifilters borrowed from my running FJ), it actually ran, but was spitting a bit back through the carbs, and sounded very rough, I guess it hadn't run in a couple of years.

Today I was thinking that it really should be running a little smoother than it was, and decided to put all the vent hoses back onto the carbs that I had left off, and reinstalled the original airbox/filter. Off came the carbs again with the help of a ratchet strap, (that rubber locating ring in the boots sure grips), hoses replaced, and proceeded to fit the airbox. Again I cursed the design of this damn thing, took 40 mins to get the airbox boots seated correctly around the carb inlets,  . This time after starting the engine sounded a lot better, no spitting, and the throttle responded quite nicely. Overall its still a long way from a clean bill of health, as the shims definatley need doing, and even though the clutch lever has good pressure, snicking into first gear was more of a *CRUNCH*. Full clutch inspection/service will be done when the engine is removed. Its done as mentioned previously 100 000kms, although how well it has been looked after is unknown. My bike is up to 130 000kms and still purrs along. I'll do a compression test on the Project '92 after the shims are done to check as well.   

[X-Ray]

Heres a link to the video of the start up,  

[ribbert]

.......Man, aren't those throttle cables a joy to get back on, flamin heck!

Ray, for the next time your doing the carbs: This is a recent PM I sent someone.

The good new is it took less than 60 secs without tools or bad language for both cables, the bad news is trying to explain it so it's clear. I'll have a go.

Jam the butterflies wide open.

Open the throttle fully (at the twist grip) it will stay there because there is no return spring yet, this makes the inner on the return cable longest.

Poke the whole return cable, from the back on the carbies, on the path it will take when hooked up.

You now have oodles of cable poking out the front with lots of slack.

Hook it up with your fingers ( you have bucket loads of slack to do this)

Remove the chock from the butterflies and pull the outer cable onto it's mounting bracket.

The pull cable is easy, hook inner up first and then pull outer into bracket.

Adjust accordingly.





As you can see, I'm not holding anything here and there is plenty of slack

Return cable first, then pull cable.
Both cable inners connected before outers mounted in adjusting bracket.

Probably as clear as mud 
If you have any questions or I haven't made something clear, PM me.

Noel

And fit them before fitting the carbs to the bike.

Noel

[ribbert]

Ray, the buffing wheels are a new toy aren't they? 

OK, you've got me on this one, I only polish what I can see!

Noel

[ribbert]

/quote]

Ray, I hope they're not your prescription lenses to the left of the photo.

Noel

[X-Ray]

  you crack me up Noel. Good tip for the cables, although I did eventually get them fitted before I put the carbs in place, but held the butterflies open with my thumb the whole time  .  I was going to paint the carb tops, but decided to polish them with my new buffing wheel toy things, what fun!  Can't leave them all grungy and dirty.  Ummm yeah, definatley not my normal specs, got them as a sample from work. 3x magnification helps a lot when looking at tiny numbers /parts etc. We sell these for around $1900.00 a set to the professionals.

[ribbert]

For anyone using these buffing wheels, it's not a bad idea to give them a "haircut" when they get like this to get rid of the long strands.
Depending on what you're polishing, they will mark your work and then you've got to polish those marks out.

Noel

[Urban_Legend]

Looking good Ray. Might polish mine next time I have the tankcoff ( then probably clear coat them) have you got noise out of the old girl yet?

Mark