My FJ1100 project

[Stoney]

I figured I should move this from the introduction thread..

I am just adding to http://imgur.com/a/Hq1va as I go along with progress pics.
Nothing exciting yet though the carbs are 3/4 back together.

Ordered a battery today, $83 delivered online for a nanogel battery with 24 month warranty vs $120 from a local shop for the usual garbage.

[Pat Conlon]

Read the specs on the new battery (max charging voltage) FJ's are known for over charging @ 15+ volts.
The oem lead acid batteries are more tolerant to higher charging voltages than the new generation batteries.

Consider a Transpo Voltage regulator mod for the cure. Info. is in the Files.

[Stoney]

Thanks for the heads up.

[Stoney]

Managed to convince the engine to fall out.
Found I had to lean the bike to either side and place an inch if wood under each side of the centre stand and about 3 inches under the front wheel, had a cradle around the motor just behind the barrels and had to pry the rear lower engine mount loose with a 4x2 while raising and lowering the motor.
Knocked up a mount for the engine stand with my newest toy (plasma cutters rock!) .. realised as I was fininshing it that it will be useless for splitting the crankcas, oh well.
Buffed the oil filller cap lol. Clean up has started.

I think I am going to remove all black from the motor, go with a plain alloy appearance,

Todays happy snaps .. https://imgur.com/a/MMLvl

[Stoney]

Not much to report, still paint stripping. Going ti buy some sand for the sand blaste and do some spot work next, shoukd also be good for getting into the fin grooves.
Took some torchlight snaps last night.

https://imgur.com/a/V95i1

Decided that all alloy is a bit too boring but I don't want to respaint black, I am going to have a think about a final colour scheme and see if the rest of the bike needs redoing as well, it is going to all be in bits anyway so why not colour it up..

[Stoney]

On second thoughts, found this nice cafe racer https://rocket-garage.blogspot.com/2015/04/fj-1200-itx.html

Looks good with alloy motor and blacked out frame rails.

[Stoney]

Chucked 20kg of sand at it at high speed.
Going to be tricky to polish to a high sheen now but the oxide was annoying me.

[Urban_Legend]

Polish the centre bit of the clutch cover. wet/dry paper up to 2000 grit, then hit with the polishing wheel. Then VHT silver for the rest. VHT clear cost to protect it all.
The would look sweet.
Mark

[Stoney]

Pulled the head and barrels, head bolts seemed very loose though I was using a big 1/2" drive torque wrench for leverage. I reckon at a little over a half turn backed off I could have removed them by hand.
One head bolt washer was missing ..

pics http://imgur.com/a/RLToS

I had a little sand from the sandblasting creep past my rag on a couple of the pots and I may well have added a few scratches turning it over with a ratchet just to get the cam bolts out.


Cams, guides, tensioner, chain are all in amazingly good shape, may well have been replaced not long before I got the bike .. I know he had it in the shop and said it cost a fair bit, I figured it was just a battery and some maintenance but maybe they had the thing in bits.

Only checked one ring end gap .. around 1.25mm .. service manual reckons 0.6mm max.

A bit of scoring on the barrels but nothing hella deep, I am not feeling like throwing $1500+ plus for a piston set and machining right this minute and cannot find a cheaper option .. there is an XJR1200 motor locally for $1600AU but the bike is simply not worth throwing that much cash at it. I would rathger cut my losses, sell it and put the money towards a better bike at this stage.

I think I will just chuck a set of rings on it, find out why the box makes a racket, throw some clutch plates at it and see how it goes.