Picked up a '91, Same Colour (Again!)

[X-Ray]

Thought I had better put up a post on my new addition. The Project '92 is still in the shed, but I knew it was going to take a long time to finish. Saw this fairly clean looking '91 online at a local dealer, price sounded right and checked it out the next morning.



It needs some cosmetic work, although the plastics are in very good condition, actually the fairing has been repaired/resprayed on one side, but it is a top job. There is a crack in the fairing under the headlight, and it looks like since the repair it has been dropped again, small chunk out near the indicator, but this will be fixed. Weighed it all up, and couldn't leave her behind, only 87000kms, and the engine is nice and tight, no noise at all. Just a few small cosmetic things to work on.


Frame and headers need some TLC. Funny that the stainless headers "corrode", as to feel them they are smooth as chrome. Some work on the buffer should get them in better condition.


More buffing/painting needed.


This little blighter was the cause of the fuel puddle under the bike the next morning. New tap from local dealer will fix it. I will also have to swap over the standard oil filter housing with my old one, someone has stripped the drain screw on this one and it weeps like a bugger.


Swapped the airbox over to my old one as the one on the bike had all of the boots siliconed up and were leaking which I think was the cause of the high idle hang when rolling off the throttle. This is only temporary of course, Randyyyyyyyyyyyy..........   This bike also had the relay mod done as well, cool!


Came with brand new wave rotors, new rear Pirelli Sport Demon, and an average front Michelin tyre.

And all tucked in.......



So all in all, some painting, detail work, few replacement parts and she is all good to go. This one will be kept stock apart from the RPM Essentials, Spin On/Risers/Unifilters/Racetech Springs/Oil Cooler,  ummmm........  One thing I am going to try is restoring the screens on all 3 bikes using a headlight restoration kit, some very good results shown on the web, will report back when I get to that stage.  

[Steve_in_Florida]

Very nice!   

Next thing you know, people will be GIVING them to you, simply because you're a worthy recipient; Shepherd of wayward FJ's.

Looks like it's in good hands. 

Steve

[jscgdunn]

"One thing I am going to try is restoring the screens on all 3 bikes using a headlight restoration kit, some very good results shown on the web, will report back when I get to that stage."  

Be really interested in seeing how this works for you.  My attempt was not good....the supplied sandpaper seemed to be too much for the plastic...maybe it is softer than headlight plastic?

Jeff

[Troyskie]

Nice one Ray, sweeeet machine!

[Bones]

Good one Ray you know, before long you'll have one for every day of the week. . Are those mufflers standard, they look like it but I thought all the later models were black.??

My screen needs a lot of work as well so interested to see how yours will turn out with the headlight kit. There's a bloke in Victoria who does a good job on them, but I don't think he's too keen on taking orders.

[The General]

Nice move Ray. I`ve tried that kit on my old corolla headlight, but wasn`t real happy with it....but I hadn`t removed the lens for both sides. Noel might give us some practical lesson in situ at Troyskie`s manshed day, I`m hoping.   

[X-Ray]

Apparently the really good headlight resto kits are the Meguirs and the 3M ones. I will try the oldest screen first which is a mess and see how it goes. As far as I know these screens are polycarbonate, and the kits are supposed to be safe for these.

Yep they are standard mufflers Tony, they have been reskinned as far as I can tell in stainless.

[Pat Conlon]

Good for you Ray. Just a bit of minor work and a new chin fairing and you're golden.
The oem decals for the chin fairing are still available from Yamaha.
The pattern to cut the heat shielding insulation for the inside of the fairing is in the Files.

I loved my non-abs '92 when I had it. It was a much smoother bike than my '84.

Enjoy that bike, ride well.

[Bones]

Hey Ray, If you get stuck for a chin fairing I've got two spare, one's a bit better than the other but they both need a bit of plastic welding and repainting.

[X-Ray]

Ooohhh Tony, I will be knocking on your door with fistfuls of cash after seeing those photos. How did you manage to pick up those as spares??

[Bones]

They came with the bike Ray, the photos make them look better than they are, but a bit of TLC will bring em up like new. I was going to attempt to plastic weld them but my welding of anything sucks big time so it was safer to just leave them alone.

[Steve_in_Florida]

I have a respect for plastic welding, especially after seeing Mike's `90 FJ at the WCR a while back. It has a certain "Frankenstein" appeal to it. Facial scars and all!

The chin fairing is WAY DOWN UNDER anyway, so who's gonna see the blemishes? 

Steve

[X-Ray]

Well, some things never go according to plan. Had to take a bit more of the bike apart last night. The fuel tank that was put on boxes in the shed toppled over when the box collapsed and the only key for the bike was in the fuel cap. Luckily the tank did not even get scratched.The key snapped off and I had to spend around an hour taking the fuel cap apart to get the bit of key out of the latch. Got that done and went to the locksmith today to get another key cut from the snapped off bit.

He was able to do this and the new key works in the fuel cap, and the seat lock, but will not work in the worn ignition switch. He said this would probably happen as a worn lock doesn't usually like fresh cut keys. Marvellous  

So tonight I spent a bit of time removing the upper triple clamp so I could take the ignition module to the locksmith on Tuesday to see if he can do anything with it. One would think you should be able to unbolt the ignition switch from the housing, but no, Yamaha installed it with blind screws so you cant remove it, has to be drilled out. So I'll see if he can make the ignition switch work with the new key, if not I'll just order a whole new one (from the UK), just means there will be 2 keys for the bike instead of one. For some stupid reason all of the 1991/1992 models on the spare parts lists have the ignition module fitted with a 3 pin plug, (3JV-82501-00-00)this one on the bike is a 4 pin, and virtually no one I can see stocks them, Fun Fun Fun. Googling found that listings for the SR500 ignition switch also lists fitment as the 3XW FJ1200s, man this gets confusing, but at least its the right one.

Good thing is I can paint the triple clamp and top part of the frame while it is out.  The things we do for our beloved FJs  

[Arnie]

Ray,

Get another key cut.  Then with ONE of your new keys run a knife or file along the bumps and notches INLINE with the length of the key.  After a couple of scrapes, try it again in the ignition.
Usually the problem with new keys cut from an old key is the sharpness of the edge.

And anyone with only one key, GO GET A SPARE before you need it!

Arnie

[X-Ray]

Thanks Arnie. Took the whole triple clamp with barrel to the locksmith again today, he said leave it with him and he'll do what he can. Half an hour later I get a text saying it's all fixed, fantastic !

He did have to do something similar to what you suggested Arnie, he cut 2 new keys but slightly modified the profile to fit the worn lock, now it operates like new.  phew!!!

Now, onto other things.....