Just joined today have a FJ1200 bought new in 89

[shockeymon]

Looks like a lot of great info here. My 1200 has been sitting in the garage for over 20 years since I started a family. I stupidly left gas sitting in it. Started it up about a year after quit riding & idled, but missing in mid range. Poured some caustic stuff ( don't remember what) in the tank hoping it would clean up carbs. No such luck. My son just bought a small Ninja & I got the itch 2 ride. See some great stuff on cleaning carbs which I'm going to try (ordered rebuild kit) even though it's probably over my head. That is what vacation time is for. What I don't see is anything about getting the carbs out of the bike. Found 1 YouTube video but it's in Japanese. Anyone know of a helpful links? My next concern is the gas tank. Just pulled it off & pretty rusty inside. Saw an article in motorcyclist on "workshop hero metal rescue rust treatment" saying it's the best stuff to use. Is anyone aware of this stuff or used it? THANKS!

[RD56]

Looks like a lot of great info here. My 1200 has been sitting in the garage for over 20 years since I started a family. I stupidly left gas sitting in it. Started it up about a year after quit riding & idled, but missing in mid range. Poured some caustic stuff ( don't remember what) in the tank hoping it would clean up carbs. No such luck. My son just bought a small Ninja & I got the itch 2 ride. See some great stuff on cleaning carbs which I'm going to try (ordered rebuild kit) even though it's probably over my head. That is what vacation time is for. What I don't see is anything about getting the carbs out of the bike. Found 1 YouTube video but it's in Japanese. Anyone know of a helpful links? My next concern is the gas tank. Just pulled it off & pretty rusty inside. Saw an article in motorcyclist on "workshop hero metal rescue rust treatment" saying it's the best stuff to use. Is anyone aware of this stuff or used it? THANKS!

This is compliments of Mr. Conlon who helped me out with the same problem I had as a newby:

Hello Rick, glad to help.
Where should I start? Have you had your tank off yet?
1) Remove seat, remove side covers, unplug wires going to fuel sender (by the battery)
2) remove (2) 10mm bolts and black oblong washers holding tank down,
3) at the rear of the tank, lift the tank up to get clearance and peek under, look at the gas line and vacuum line going to petcock (left side) put a towel down on the top of the engine to absorb a dribble of gas when you disconnect the gas line at the petcock, disconnect the vacuum line at the petcock..You don't have to turn the petcock off...it's automatically off when engine vacuum is not present.
You might (or might not) have an additional vapor line you need to disconnect...I don't.
4) now pull the tank back then lift the tank off the bike. Put a towel down to prevent scratches and store the tank upright with a block of wood under the front of the tank to keep the tank top level....so no fuel leaks out the cap and ruins your paint.

So now the tank is off...See the airbox? That is next.
Remove the right side airbox cover,
5) here's a link for discussion on removal/replacement of the airbox:
http://www.fjowners.com/index.php?topic=10410.msg100806#msg100806
Now your airbox is off...

See the white throttle cable connector slider box? Where the 2 cables (push/pull) connect?
6) Open up that box with the 3 small Phillips screws. Do one at a time. Be careful they are easy to drop and lose. Disconnect the slider connectors from the cable ends. Now your carb cables are free.
7)  Disconnect the choke cable at the carbs (right side)
8 ) Pull up the 4 small choke vent hoses up from the back of the engine, pull up the 2 larger float bowl vent hoses from the back of the engine, you will remove/replace these hoses from the carbs after you have the carbs off.
9) loosen the 4 Phillips screws on the 4 clamps holding the carbs to the rubber boots
10) Now straddle the bike (best position), wiggle up and down on the carbs while pulling the carbs back to you and the carbs should come free of the boots. Lift the carbs with the hoses out of the bike. The heat shield stays in place.

[movenon]

Welcome ! Your FJ sounds like it's part of the family ! Keep her and get her running .
George 

[Pat Conlon]

Hey Rick, thanks for the compliment..

Hey Shockymon, welcome back home....
Your procedure for carb removal is almost the same as I described above for Rick but, you have a '89 which has a fuel pump...Rick has a gravity flow FJ, so, to take the tank off it's a bit different.
Replace #3) above with this: When you remove the right side cover you will see the fuel pump and 2 fuel lines attached. The top fuel line comes from the tank and the bottom fuel line goes to the carb.
Use a rubber shod hemostat or small needle nose vice grips (rubber shod) and clamp the top fuel line about 6" from the fuel pump and disconnect that line from the fuel pump. Find a container and drain your tank by releasing the clamp......then you can get the tank off.

You will have your work cut out for you to clean that tank.....but at least you have a fuel pump FJ that has a real fuel filter....that will help trap any lingering crud...
We who have gravity flow FJ's ('84-87) don't have the luxury of a fuel filter....only a screen on our petcock.
Cheers ......Pat

[FJmonkey]

Welcome to the asylum, that old fuel will need attention to detail to get properly cleaned out. Make sure you get to all the tiny holes and places it gums up. Since you need such a through cleaning, consider the fastener kit from RPM Click Here. It replaces all the soft screws with Stainless hex socket fasteners. The photo does not show the complete kit, it replaces all the crappy screws and some O-rings that wear out with age.

[shockeymon]

Thanks a lot everyone. I goofed around before posting & got the tank off & drained. On cleaning out the tank can I take off the petcock & pour cleaning agent through it with gas cap shut & tank upside down to clean it out? I already ordered the kit you referred to for carbs. Thanks for info on tank removal. By the way couldn't believe it but tires actually held air to make it easier to move around garage.

[yamaha fj rider]

Welcome to the forum. Original owners are rare but there are a few of us here. Good to hear that you are getting it running again. Once you get it running again, think about replacing rubber things like tires, break lines, clutch slave cylinder seals. Hope this helps.

http://www.fjowners.com/index.php?topic=12098.0

Kurt

[aviationfred]

Welcome to the group. 

Another note for things to look at before you get back on the road. You mentioned that you aired up the tires and you were surprised that they held pressure. If they are the same tires that were on when the FJ went into storage, replace them immediately before you ride. The rubber will be rock hard and offer next to zero grip on the road.

Fred

[wm_Reed]

Welcome to best forum around.  I am also an original owner of an 89 FJ.  The information in this forum has been tremendous.  The carb screw kit from RPM is well worth it.  Also the spin on oil filter.  As others will tell you, replace the brake lines and the tires. 

Enjoy,
Bill

[Scottericsonon]

As other people have said.... Replace the tires!
I resurrected a BSA a couple years ago that had been sitting since 1973 and I took it around the block on the 40 year old tires (just to make sure the trans shifted etc)


Man.... Talk about SCARY!!!

[shockeymon]

Thanks everyone. I gave the carbs a shot but did the 1 thing you don't want to do & broke off a float pillar. Broke down & spent more than I can afford & sent carbs out to pushrod factory for cleaning & tuning. Should get them this week. Still working on cleaning crap out of tank. There must be 50 posts on the net on how to do it, however there really isn't a clear cut "best way" I put a lot of ozy clean with hot water through it that took care of the vast majority of big stuff and am now  using evapo rust on it. Haven't read of any clear cut winners on coatings and some people opt to just keep the tank filled. Still undecided. Any advice would be welcome.
Thanks