Hi All, from Co. Down, Ireland

[Jim_C]

I've just bought a 1991 FJ1200 ABS. I knew it needed a little work, but it wasn't until I got up close and personal with it that I realised just how neglected it had been

Body work & frame are in excellent condition for it's age, however, so far I've had to rebuild all brake calipers with new seals & pads etc., overhaul the ABS pump (as it seized on my second short trip out), new rear shock, valves & carbs sorted, throttle cable etc etc. But sure this is part of the fun at least when I have it sorted I'll know I've a good bike under me. I use to have an FJR1300 then moved to Goldwings for a few years, but there's just something special about the semi-retro look of the FJ.

Maybe some-one could help me with my first stumbling block. I rebuilt the front brake master cylinder using the Tour Max kit ref. 280107, however, it's a slightly different set-up than the original and I assembled it wrong, this caused the spring to gamage the primary seal I have another kit ready to install, however, I'll leave this for my mechanic this time. Does anyone have fitting instructions for this kit?

Also the front brake system seems to be airlocked.... anythoughts as to where's the mostly spot and how to clear it?

Many thanks for your thoughts!

[nurse]

Top a da marnin to ya! i feel i can be slightly over familiar seeing as my family originate way back from somewhere near Cork!  Welcome to the forum.

Before you do anything read up on everything on here!!  Then once you think you have read enough read some more!! Dont bother wasting time and money with the brakes work, strip out all of it (save weight) ditch the front MC and get a fazer MC (i forget the year but i used one from the original fazer -about a 1999?) and blue spot calipers from R1/R6 or similar, braided lines, excellent stopping, much better than the OEM set up and it will be cheaper. 

Strip out abs pump save more weight.  I have put some info on here about what i did.

In answer to bleeding question use a syringe or similar fluid driver and do it backwards!! 

Any question will have already been answered on here, if not there is loads of help around!

[rktmanfj]

Also the front brake system seems to be airlocked.... any thoughts as to where's the mostly spot and how to clear it?

Many thanks for your thoughts!

Clean the m/c and flush the system.  It likely has a blockage in one of the ports, or if you still have the OEM lines, one of them could be causing the problem.  The OEM lines were long ago overdue for replacement anyway,

[yamaha fj rider]

Welcome to the forum and listen to the advise that has been given. Good stuff. 

Kurt 

[Jim_C]

Before you do anything read up on everything on here!!  Then once you think you have read enough read some more!! Dont bother wasting time and money with the brakes work, strip out all of it (save weight) ditch the front MC and get a fazer MC (i forget the year but i used one from the original fazer -about a 1999?) and blue spot calipers from R1/R6 or similar, braided lines, excellent stopping, much better than the OEM set up and it will be cheaper. 

Strip out abs pump save more weight.  I have put some info on here about what i did.

I really don't want to do away with the ABS, I just like knowing it's their, you never know when you might need it. I was glad of it once on a ST1300A that I used to own, very wet road and someone pulled out of a side road. If it wasn't for the ABS i would have def. been down.

Anyhow, if I upgrade the front m/c, is there any that work well with the 3 wired ABS micro switch?

Thanks!

[FJmonkey]

Welcome to the Kookaloo loving 1100/1200 CC scooter club.

[nurse]

 
I really don't want to do away with the ABS, I just like knowing it's their, you never know when you might need it. I was glad of it once on a ST1300A that I used to own, very wet road and someone pulled out of a side road. If it wasn't for the ABS i would have def. been down.

Anyhow, if I upgrade the front m/c, is there any that work well with the 3 wired ABS micro switch?

Thanks!

Well you pays your money and you takes your choice.  In your situation i would hazard a guess that you would still be down anyway coz the FJ ABS is not up to much! (by much i mean sweet FA)  It was a very early system and not very effective.  Mine was in tip top condition with only 4000miles on it and it sucked, badly.  The only reason yamaha fitted ABS was because the brakes were so poor to start with! 

Cant help with the micro switch enquiry as i took it all off.  If you had ABs on the FJR and Goldwings you mentioned you are maybe using this as a comparison, but dont the FJR system was lightyears ahead of the FJ, cant comment on the goldwings as i have riden one!

Good lucj with whatever you choose to do! 

[yamaha fj rider]

Nurse is right, first generation ABS is not good. Probably doesn't work any more. Most quit working in the first year or two. Yamaha, BMW, others quit working or were unreliable. Having a good experience with an other bike is not this bike. Hard to give up on the ABS but you will come to understand that it's better to good brakes than poor ones. I know how you don't want to give up on the ABS, I was the same way six months ago but when you set the emotion aside and look at the facts it becomes very clear. Update the brakes on one of these and they can stop with a modern bike and that will keep you out of an accident. From the owner of a 93 FJ1200 formerly ABS. Please understand when I bought my FJ (new in crate 1994) it being ABS was one of the things I loved about it. I understand your not wanting to give this up. Hope this helps? If you have any questions post them or send me a PM and I will do my best to answer them. If i don't have the answers some one here dose.

Kurt