Bringing baby FJ back to life

[JPaganel]

So, as I posted earlier, I have acquired a non-starting, non-running FJ600 for a princely sum of $300 and I have started working on making it run again.

The previous owner said he cleaned carbs, but could not make it run, and then, it mystically lost spark.

My first order of business was to ditch the horrible oldschool glass fuse fusebox. Glass fuses in and of themselves are not a problem, but the Yamaha boxes used before mid-80s had really bad metal used for clips. This metal gets brittle, fuses get loose, and any attempt at bending the clips breaks them. Or, sometimes they just break on their own. FJ1200, to my knowledge, always came with the ATC fusebox that does not have these issues. So, I transplanted a new ATC fusebox into the FJ600 to match all my other old Yamahas.

Still no start.

So, I disconnected the black/white kill wire from the ignition box. This got me spark. This also tells me the problem is in the safety circuit, which is kickstand switch, clutch switch, neutral switch and the relay. So far I found the clutch switch wrecked. Not sure about kickstand switch or relay yet. I am hindered by lack of a correct wiring diagram, the ones in the Clymer manual don't match what I see on the bike.

Bike ran with the the safety circuit disconnected, but only at idle with the choke all the way out. Giving it any gas would stall the engine. I pulled carbs and found that the guy's idea of cleaning them was to wash out the bowls and strip some screw heads. First emulsion tube I pulled was completely clogged.

So far, I got some screws on order and I am trying to find a replacement clutch switch from some place other than UK. International shipping sucks.

[Dads_FJ]

Re: the switch you seek, I saw a couple fj600s at Sport wheels In Jordan yesterday while I was there...

Pics to follow.

[aviationfred]

According to Partzilla, the clutch switch and the side stand switches are available

http://www.partzilla.com/parts/search/Yamaha/Motorcycle/1985/FJ600N/HANDLE+SWITCH-LEVER/parts.html

http://www.partzilla.com/parts/search/Yamaha/Motorcycle/1985/FJ600N/ELECTRICAL+2/parts.html

Fred

[Dads_FJ]

Here it is...



Side cover anyone?



The place is amazing



More pics of our day here:

http://s208.photobucket.com/user/campsimonette/library/Sportys?sort=3&page=1

[TexasDave]

John couldn't you find an FJ project bike that would not take quite so much work?       Happy I wasn't there with you as I would have spent all my money. Lots of old school projects waiting to get started there.  Dave

[JPaganel]

 Happy I wasn't there with you as I would have spent all my money. Lots of old school projects waiting to get started there.  Dave

They won't sell you a bike out of there. For sale bikes is a different section of the place.


They have a ton of stuff, but are horribly disorganized. They have no idea what they have on hand, and so if you ever call them, they actually send a guy out in the yard to go take a look.