1992 FJ12 Project/Resto

[X-Ray]

Well, I was reminded on the weekend I haven't started to document my project, so heres a start. I recently acquired from our friend Doug (Baldy), a bike (100 000 kms) that he had bought a year or so earlier. The previous owner had not looked after it well at all, and I was really only wanting the Givi luggage from it, (detailed here http://www.fjowners.com/index.php?topic=12824.0), but Doug being the generous soul we know said keep the whole bike.

So, after looking this poor machine over thoroughly, it was decided that only a full ground up restoration would work. So, first job was to jump onto some near mint plastics found in the US to replace the mismatched ones that came with it, and try to start it.   It wouldn't start but did deliver a healthy stream of fuel from one of the overflows. Ok, so carb overhaul was going to be the first job before trying to start this beast. Doug did say the bike had been sitting for a while, and the gummed up carbs/fuel tank would back this up, plus the fuel was pretty off.  I haven't pulled apart a set of carbs before, but armed with the files from this site and others, set to it. They are pretty logical things when you look at them, nothing too scary about them at all. After discovering why the slides wouldn't move freely, all small parts were removed and soaked in acetone for a week, mostly worked apart from the emulsion tubes which were clogged solid.  At this stage I said if I'm going to do this properley, new kits are going into these carbs. We can't buy any proper "carb dips" here, so a few cans of carb cleaner took care of the external and internal cleaning job.

I'm ordering some carb kits soon, plus a heap of other parts will be needed to do this job properley.
The person Doug bought this bike from had jammed different screws into fairing mounts, bits were missing, the sidecovers, scoops and dovetail I received had been painted a crap faded blue, its going to be a big resto, but I'll just take my time and do it as best I can. The good thing is I have my bike to refer to if I get stuck anywhere during reassembly etc. It will be a long term job, ( up to a year ), but I'm looking forward to it.       Heres some piccies to start --

As Doug Bought It.


Home



These cost a bit, but were worth it.


This syrup used to be fuel


Dirty Carb Teardown









Starting to look Cleaner



A small side benefit to having the same model bike is I could possibly donate some parts to the resto bike, and buy myself some nice shiny new bits!  

More to come.................

[FJmonkey]

Looking good, always love to see a bike restored with love and attention to detail. Keep the posts coming...

[ribbert]

Hey Ray, I'll swap you a polished screen for that RHS scoop.

Great report. Have you assessed the condition of the motor yet. 100,000km's shouldn't be a problem. I'm surprised at how gunked up the carbies were with our fuel, or is that from the 10% banana juice they blend it with in QL?

Noel

[X-Ray]

Now that I've started this Mark, I will have to keep going, it will cost a bit to do though.  

Mmmmm, polished screen Noel,    I know what your polished screens look like. Tempting but unfortunately no. However, you can HAVE the faded blue coloured scoop if you want it. It needs repainting, thats why I ordered the other plastics. The motor has done less than my bike, but I still haven't heard it run. First priority is to clean/rebuild the carbs, do a complete oil/filter change, and hopefully get it started. I have been told the shims needed doing, but motor is otherwise good.

[ribbert]

Tempting but unfortunately no. However, you can HAVE the faded blue coloured scoop if you want it. It needs repainting...

Thanks Ray, but that is the problem I already have, repainting. I dropped my bike a while back and damaged the paintwork on the scoop.
FJ#2 ('93) however needs a RHS scoop in you're serious. I have a photo of Pat's 1100 on my wall that seems to be the paint job I have settled on so colour doesn't matter.

Like yourself, I am doing a similar resto on the second bike. Unlike yourself, I have not progressed other than to pinch the motor for my bike after it blew a base gasket. It had a 145,000k's on when I fitted it a few years back. It goes like the clappers, uses next to no oil and compressions are good (audio check) It probably has another 30,000+ on it by now.

Noel

[X-Ray]

Yep, I don't need that scoop Noel. Someone has actually painted directly OVER the original FJ colour, and after I realised there was no way to remove this without damaging the paint underneath, ordered the replacements. (got lucky with a parts wreck overseas).

[FJools]

Hi Ray

will be following this restoration with interest as there are some parts I need to refurb on my FJ.

Are you planning to dip the carb bodies in an ultrasonic bath ? I hear that soda blasting is a good non intrusive method of cleaning up the outer surfaces without leaving any grit or residue that won't wash off with water.

[X-Ray]

The carb bodies I just cleaned inside and out with the spray after soaking them for a few hours in hot water with dishwashing liquid. Read so many articles on dips and lemon baths etc, but I think these have turned out quite ok. Still have to order the rebuild kits from Motorcycle Spares Warehouse in Vic, our current exchange rates make them too expensive to buy from RPM presently.

There are a few places around I checked out that dip carb bodies for around $80 and do a good job, but I decided to do it myself. 

[FJools]

Ray

My last prompted me to splash out on soda blast rig and media. (I must keep off ebay )

BTW -
If the lower belly pan is in reasonable condition and looking for a new home I'm interested..........

Jools

[X-Ray]

Mmm, the lower belly pan has snapped in 2 places, and I have to repair/paint it to stick on this bike. I'm going to do that with all of the damaged/painted over plastics and try to get them back to something nice, they are a mess. The two scoops have a thick layer of bog smeared over the back of them, they really need some work.  

Edit: Noel, have you seen this scoop?  http://www.ebay.com.au/itm/like/Yamaha-FJ-1200-Right-hand-side-panel-air-scoop/171639293829?hlpht=true&ops=true&viphx=1&_trksid=p2050601.c100125.m2672&_trkparms=ao%3D1%26asc%3D20140212104718%26meid%3Dbc3153e3a2824e2fa5d67dde315a4ffe%26pid%3D100125%26clkid%3D3857848129708186319&_qi=RTM2003752

[FJools]

Ray

good ones seem to be in short supply.

I repaired mine by creating the missing part from an old LC side panel but my armature plastic welding gave way
while I was having all the exhaust woes, and after I had painted it 

It will give a second chance to do it properly this time.

[ribbert]

Edit: Noel, have you seen this scoop?  http://www.ebay.com.au/itm/like/Yamaha-FJ-1200-Right-hand-side-panel-air-scoop/171639293829?hlpht=true&ops=true&viphx=1&_trksid=p2050601.c100125.m2672&_trkparms=ao%3D1%26asc%3D20140212104718%26meid%3Dbc3153e3a2824e2fa5d67dde315a4ffe%26pid%3D100125%26clkid%3D3857848129708186319&_qi=RTM2003752

Thanks for the link Ray, but the close up shows it to be much worse shape than mine and as for FJ#2 that needs one, some bloke in QL promised me one, thanks anyway.

Noel

[Timbo-1]

Wots happening...wots happening....

[The General]

Wots happening...wots happening....

[X-Ray]

Unfortunately no progress on the bike so far apart from having the carb kits turn up. I really have to clean out my shed and install some big workbenches to keep things in order. This is going to be a bare frame tear down/rebuild, and I have no room to do it. 20 years worth of "storage" is being moved out over the next few weekends, and then I can get stuck into the resto properly