87 FJ running again

[petetb154]

About a 15 mos ago I decided to dust off my 87 FJ1200, (62k miles) which I have owned since 1990, and get it running like new again. See my intro post: http://www.fjowners.com/index.php?topic=11247.msg113079#msg113079

And it's first picture after a long hibernation (April 2014)


Well, I didn't do it quickly, but I spent a small fortune at E-bay, Motorcycle-Superstore, Bike Bandit, Amazon & of course w/ Randy @ RPM.
I made the following updates:

Front End:
- 1992 FJ1200 front wheel, new wheel bearings & power coated black satin
- Continental Motion Tire 120/60-17
- 1990 FJ Fork Lowers w/ RPM seals and bushings kit
- RPM Fork Valves
- Race Tech springs
- 2000 R1 blue dot brake calipers and master cylinder
- Dasheng Tieliang wave brake rotors
- EBC sintered brake pads
- New speedo cable

Rear End:
- 1992 GSXR1100 rear wheel, new wheel bearings & power coated black satin
- Continental Motion Tire 120/60-17
- 40t JT Rear sprocket, 17T JT Front sprocket
- RK 530 O-ring Gold chain
- 1990+ FJ Chain slider (had to install 2 riv-nuts in swing arm for mounting)
- RPM rear shock
- 1990 GSXR 750 rear brake caliper & wheel spacers
- EBC sintered brake pads
- FZR 1000 rear brake arm (with new lower attach point welded to swing arm)
- Extreme Shop GSXR wave rear brake rotor

Engine:
- New XJR Starter
- New Uni air filter pods
- Carb rebuilt kit w/ new screws, brass parts & jets (40/115), and sync'd
- Rebuild clutch slave cylinder
- Spin on oil filter kit

Misc:
- LED Instrument panel lights
- New/used fuel gauge (replaced a bouncy gauge)
- New battery
- plastic welded all cracked parts
- created a new right fairing protector using a 3d printer (can't buy them anymore!)
- safety wired petcock
- fixed a million other little things.

I finally got to take it around the block the other night.  I've only put a few miles on her so far, but I can say that it feels like a totally different machine.

Here are a few pictures, disregard the defects in the paint for now.





Next is a a full shakedown and de-bugging, will probably take a few hundred miles to debug the little stuff.
After that, I'll re-paint the plastic w/ OEM colors & decals and powder-coat all the metal parts black or silver.

Then, finally, will have invested more in the rebuild than it cost when it was new!

Thanks for all of you who helped.  

[Pat Conlon]

Well done Brian! I can imagine that your bike feels much different now.
You know that a RPM fork brace will really tighten up that front end.
Don't forget, on your front fender side tabs, put some washers between the plastic tabs and the aluminum fender mounting tabs on the forks, to compensate for the old brake hose bracket you removed.
These washers and the fork brace will help prevent your plastic fender tabs from cracking.

Again, great job. I love to see these kinds of posts. Update us when you get the paint done.

Enjoy that bike! Ride well.

[Steve_in_Florida]

Looks good from here!



Steve

[aviationfred]

Very well done. 

Just an observation...... On the '87 model, I always wondered why Yamaha went with a Red front fender. With the color pattern I would think a Silky White fender would look good.


Fred

[petetb154]

Well done Brian! I can imagine that your bike feels much different now.

You know that a RPM fork brace will really tighten up that front end.

I agree, a new fork brace is in order. I looked at he RPM brace and while everything that I have purchased from Randy has been of excellent quality,  I just struggle paying that much for a hunk of aluminum. Ive been browsing one on ebay for $36.00. Has anyone tried one of these?
http://www.ebay.com/itm/FORK-BRACE-YAMAHA-FJ1200-FJ-1200-A-FRONT-FORK-BRACE-/251994406329?hash=item3aac097db9&vxp=mtr

Don't forget, on your front fender side tabs, put some washers between the plastic tabs and the aluminum fender mounting tabs on the forks, to compensate for the old brake hose bracket you removed.

Good reminder. I'll do that tonight. Thanks!

[FJ1100mjk]

I agree, a new fork brace is in order. I looked at he RPM brace and while everything that I have purchased from Randy has been of excellent quality,  I just struggle paying that much for a hunk of aluminum.

Another fork brace option...

http://www.fastfromthepast.com/25-0033

Probably isn't as good as the RPM one though. Same goes for any rear shock other than RPM's 

[FJmonkey]

I agree, a new fork brace is in order. I looked at he RPM brace and while everything that I have purchased from Randy has been of excellent quality,  I just struggle paying that much for a hunk of aluminum. Ive been browsing one on ebay for $36.00. Has anyone tried one of these?
http://www.ebay.com/itm/FORK-BRACE-YAMAHA-FJ1200-FJ-1200-A-FRONT-FORK-BRACE-/251994406329?hash=item3aac097db9&vxp=mtr

The fork brace on Ebay is thinner than the RPM design but thicker than the flimsy sheet metal plate Yamaha gave us. It will help prevent the forks from bowing but it will not resist the torsional forces as well as the RPM brace. I wonder why it was made in 5 pieces. I guess the center can be changed out to fit different width forks and the clamps to fit different diameter forks. Just my observation on it.

[aviationfred]

Well done Brian! I can imagine that your bike feels much different now.

I agree, a new fork brace is in order. I looked at he RPM brace and while everything that I have purchased from Randy has been of excellent quality,  I just struggle paying that much for a hunk of aluminum. Ive been browsing one on ebay for $36.00. Has anyone tried one of these?
http://www.ebay.com/itm/FORK-BRACE-YAMAHA-FJ1200-FJ-1200-A-FRONT-FORK-BRACE-/251994406329?hash=item3aac097db9&vxp=mtr

I believe George, (movenon) has one of these fork braces.


Fred

[Troyskie]

  great work! I bet your Effie feels tight as a seagulls bum now

[FJmonkey]

You still have time to shake her down and plan to make one or both WC rallies. A new '87 owner is making the NorCal rally and I hope to make the Renegade rally on my '89.

[movenon]

Well done Brian! I can imagine that your bike feels much different now.

I agree, a new fork brace is in order. I looked at he RPM brace and while everything that I have purchased from Randy has been of excellent quality,  I just struggle paying that much for a hunk of aluminum. Ive been browsing one on ebay for $36.00. Has anyone tried one of these?
http://www.ebay.com/itm/FORK-BRACE-YAMAHA-FJ1200-FJ-1200-A-FRONT-FORK-BRACE-/251994406329?hash=item3aac097db9&vxp=mtr

I believe George, (movenon) has one of these fork braces.


Fred

Yes I have one.  Seems to work but I am not a hard rider.  It adds enough rigidly in the forks for me.  My main goal is to help limit fork movement to keep my front fender from flexing and breaking over time. 
George

[Tiger]

http://www.ebay.com/itm/FORK-BRACE-YAMAHA-FJ1200-FJ-1200-A-FRONT-FORK-BRACE-/251994406329?hash=item3aac097db9&vxp=mtr

I have one on my '92...which I originally had on my '85. It's been around 'The Dragon', etc and works just fine...

John.

[Tiger]

http://www.ebay.com/itm/FORK-BRACE-YAMAHA-FJ1200-FJ-1200-A-FRONT-FORK-BRACE-/251994406329?hash=item3aac097db9&vxp=mtr

I have one on my '92...which I originally had on my '85. It's been around 'The Dragon', etc and works just fine...

Congratulations on a job really well done...Enjoy

John.

[petetb154]

http://www.ebay.com/itm/FORK-BRACE-YAMAHA-FJ1200-FJ-1200-A-FRONT-FORK-BRACE-/251994406329?hash=item3aac097db9&vxp=mtr

I have one on my '92...which I originally had on my '85. It's been around 'The Dragon', etc and works just fine...

John.

Just ordered one tonight. $42 shipped. Thanks.

[FJ1200W]

I ordered one today as well - http://www.ebay.com/itm/FORK-BRACE-YAMAHA-FJ1200-FJ-1200-A-FRONT-FORK-BRACE-/251994406329?hash=item3aac097db9:g:nDgAAOSwoudW8NgE&vxp=mtr

On top of dragging this thread up from 2015!