San Diego CA, USA I could use some help with a 1989 FJ1200 model 3SK

[CafeNervosa]

I recently bought a 1989 FJ1200 model 3SK. 
The first day I got it, the speedometer cable fell out, so I need that replaced. The bike shop I used has not been able to get a replacement.
The turn signal stopped working also, so I want that turn signal repaired before joining any group rides.  The shop near me had the bike two times to fix the turn signal and it is still not fixed.
I am reluctant to work on the bike without help since the plastic seems to be super brittle.  The fairing is still shinny and pretty scratch free.  The two rectangular covers over the main fairing bolts are loose.  I am thinking of looping a ty-wire or rubber band around the six insert to stop the rattle. 
The front fender bolt mount was broken when I picked the bike up from the shop one day.  I mended the bolt hole piece for the front fender using JB epoxy.

The bike has a aftermarket FR1 dual exhaust.  The prior owner have me the original black slip on mufflers.  He also included a Super Trapp Stainless Steel four-to-one exhaust.  The center stand works great.  The cage inside the left slip on muffler is loose and rattles around inside the cylinder.  I am thinking of installing the Super Trapp Stainless Steel four-to-one exhaust.  but I want it only if the 4-to-1 is compatible with the center stand.

I am excited to have such a competent bike, but I need these help in San Diego with these small items since the bike shop has let me down.  I'll post pictures once I figure out how to do it.

[movenon]

Welcome to the group ! Well the center stand works  .. Speedo cables are available on e bay and from Motion Pro. http://www.motionpro.com/
They are inexpensive.  Need more information on the turn signal. All signals ?
Your bike is fixable. It sounds like it needs some TLC. Good on you for asking questions.  Its cheaper than braking something.  Lots of help here and there are a few members down your way.

Sounds like you better learn to do your own work or at least find another mechanic.. The front fender is a weak point. That tab breaks easily. Most just glue them back together.  New fenders are still available, also some convert to a Bandit fender.

Post some pictures if you can showing the covers you are referring to.  It will help you to get a copy of the owners manual and a service manual.  Both can be found on line. They are not the best copies but usable.
George

[CafeNervosa]

A photo of the side covers is here:
http://fjowners.com/gallery/6/3934_16_03_14_8_16_24.jpeg

There is one on each side.

[CafeNervosa]

I found the speedo cable
http://www.motionpro.com/motorcycle/partno/05-0030/

[CafeNervosa]

Here is a photo of the bike.
I like the dark blue / gold scheme.

http://fjowners.com/gallery/6/3934_16_03_14_8_08_56.jpeg

Can anyone point to photos showing how to hang my helmet from the helmet latch without resting the face shield on the muffler.  I can wedge the turn signal into the helmet but that puts lots of stress on the turn signal.

[movenon]

If you are referring to the bumpers on the side scoops.  You might try some Velcro ? Or some double sided foam tape on the back side.
George

[Pat Conlon]

Here is a photo of the bike.
I like the dark blue / gold scheme.

http://fjowners.com/gallery/6/3934_16_03_14_8_08_56.jpeg

Can anyone point to photos showing how to hang my helmet from the helmet latch without resting the face shield on the muffler.  I can wedge the turn signal into the helmet but that puts lots of stress on the turn signal.

I can not use the helmet lock without the helmet touching either the F1R can ('84) or the Kerker can (92) so what I do is to put one glove in the helmet, and the other glove I put between the can and the helmet.
This is not a problem with the stock exhaust cans, only with certain aftermarket exhaust.
Cheers Pat

[markmartin]

The two rectangular covers over the main fairing bolts are loose.  I am thinking of looping a ty-wire or rubber band around the six insert to stop the rattle. 

Black anodized #6, pan head, sheet metal screws work well to hold the bumpers in place and rattle free and look like they belong there.  IMHO.

[ribbert]

A photo of the side covers is here:

There is one on each side.

Those covers FIT loose, even brand new they are a loose fit. They have been known to fall off though.

My solution was this:



Velcro dots.

Noel

[CafeNervosa]

Thanks all for the helpful advice.  I will consider either the Black anodized #6, pan head, sheet metal screws or the velcro solution.
I have ordered a Shop Manual
Yamaha FJ1100 & FJ1200 84-93 by Penton Staff     $14.37  Sold by: betterworldbooks_

New issue:  The fuel reserve switch failed me yesterday.
Backstory:  I have always suspected the fuel gauge.  After filling the tank, the gauge does show a full tank, but after only what seems like a short ride, the needle shows the tank is empty.  I drive for quite a few mile with the gauge showing empty.  When I sense the gas is running out, I switch to reserve using the electronic fuel reserve switch and go fill up.  (I still have no speedo and odometer to judge when it is time to fill up)
I asked the local shop to test the fuel gauge.  I guess I failed to give a detailed description of the problem.  They reported that they jiggled the arm in the tank and said the gauge was working fine. The fuel reserve switch failed me yesterday so I had to get AAA to bring me gasoline.
Any tips on a diagnostic test that reveals the problem and possible solutions would be nice.

I am looking forward to getting the shop manual.

[FJmonkey]

New issue:  The fuel reserve switch failed me yesterday.
[sniped]
Any tips on a diagnostic test that reveals the problem and possible solutions would be nice.

This was a hot topic last year, might help you get a grip on the sender and reserve switch. http://www.fjowners.com/index.php?topic=9996.0

[CafeNervosa]

Reserve fuel function debate was way long and I still don;t know where to place my volt meter leads.
I have the original owner's manuals, but I will look forward to getting the service manual for a 1989 FJ1200 3SK.

On another topic, is the bike designed to allow the gauges to move separate from the fairing?  When I press on the top of my gauges is moves a little relative to the fairing surrounding it.

[ribbert]

Reserve fuel function debate was way long and I still don;t know where to place my volt meter leads.
I have the original owner's manuals, but I will look forward to getting the service manual for a 1989 FJ1200 3SK.

On another topic, is the bike designed to allow the gauges to move separate from the fairing?  When I press on the top of my gauges is moves a little relative to the fairing surrounding it.

Boy, do I remember that debate!  However, that was all about the function of the switch nothing to do with checking the switches operation. Simply, it's a rocker switch. One position will see power flowing in one side and out the other, the other position will show power one side only. This should be straight forward however you check it, volt meter, test light or continuity tester.

They are a really simple switch and being brass and semi exposed to the elements, with current passing through them, they are prone to a build up of grunge.
Someone posted an excellent photo of the disassembled switch here in the last day or so.

There is almost nothing to go wrong with this type of switch other than the contacts getting dirty. The switches don't see a lot of use which contributes to their long life but also makes them more prone to corrosion on the contacts.

If you are unsure about how to test it, maybe just clean in up and re install it first. Not much of a job and most likely will fix it.

Gauges:  Yes, they are meant to be "loose." A number of people here have tightened them with packing washers and vibrated their instruments to bits.

Noel

[ribbert]

.......and I still don;t know where to place my volt meter leads.

..........or you could squirt some WD40 into it and operate it 20 or 30 times, or ask you local garage or auto elec to test it, I doubt they would charge you as it's a 2 second job.

Noel

[CafeNervosa]

Thanks ribbert,
I really look forward to getting the shop manual.  I will look around for the photo of the dissasembled switch .

Has anybody tried these wind screen screws available on amazon.
Motorcycle Motor Sport Windshield Windscreen Bolt Screw Kit 10PCS Blue Fit For Yamaha FJ1200 nurohne ABS alle
by GAO.
http://www.amazon.com/dp/B00HF164S4?_encoding=UTF8&psc=1&s=automotive

My windshield fasteners look to be UV damaged, one broke just by touching a screwdriver and these blue or gold aluminum looks like they it could improve the looks.  I don't know how I can get to the back side of the lower four fasteners.

As for the turn signals, the shop thinks the problem is not the flasher, but the other seals component that does the self canceling.  I returned it to the shop so he can have another crack at finding a solution and to install the new speedo cable.
Derek