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FJ1300 with a European Twist

Started by aviationfred, November 25, 2015, 09:14:27 PM

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racerrad8

Quote from: Pat Conlon on December 16, 2015, 03:48:14 PM
Oil drains? Ok, yep, I haven't seen those on FJ pistons before

Yes, as the oil ring scrapes the cylinder wall it allows the oil to flow through the holes and back to the crankcase instead of pooling under the ring.

Randy
Randy - RPM

FJ1200W

Quote from: aviationfred on December 16, 2015, 06:46:58 PM
I measured the pistons.....

Old pistons-77mm

New Pistons-80.5mm

Both the old and new pistons have the holes




Those new pistons look shorter - that will reduce the stroke!



:shout:



Anyone fall for it?
Steve
Columbia, Missouri
USA

aviationfred

Quote from: FJ1200W on December 16, 2015, 10:28:24 PM

Those new pistons look shorter - that will reduce the stroke!

[/quote]


The stroke will be the same.....The skirt has been shortened, making a lighter piston to reduce reciprocating mass.

3mm larger diameter with less weight than the OEM piston.

Fred
I'm not the fastest FJ rider, I am 'half-fast', the fastest slow guy....

Current
2023 Moto Morini X-Cape 650
2008 VFR800 RC46 Vtec
1996 VFR750 RC36/2
1990 FJ1200 (1297cc) Casper
1990 VFR750 RC36/1 Minnie
1989 FJ1200 Streetfighter
1985 VF500F RC31 Interceptor

PaulG

Speaking of pistons... I just read this in the Nov/15 issue of Cycle World.  Don't know if it is relevant to any of the FJ projects on the site but interesting nonetheless - to a hamfisted backyard basher like me anyways.



http://www.cycleworld.com/2015/10/14/ask-kevin-modern-piston-on-older-four-stroke-motorcycle-engines/


1992 FJ1200 ABS
YouTube Channel Paul G


nchattaway

Hmmm, I know someone with less cash than Fred who is probably going to need a good cylinder block with smooth bores and matching pistons. Er, it's me. Will the standard FJ1200 cylinder block bolt up as a replacement for a smoking FJ1100 motor? Is this the only difference between the FJ1100 and FJ1200 motors?

If the answers to my questions are "yes", then I'm wondering if you're looking to sell, Fred? I live in Australia, so freight could be an issue I guess.

Cheers,
Nathan

Pat Conlon

Nathan, what are your (warm) compression numbers?

Perhaps you just need new valve seals. With a bike taken out of storage, you will want to ride it for awhile.
The smoke just might clear up with some active riding.
1) Free Owners Manual download: https://tinyurl.com/fmsz7hk9
2) Don't store your FJ with E10 fuel https://tinyurl.com/3cjrfct5
3) Replace your old stock rubber brake lines.
4) Important items for the '84-87 FJ's:
Safety wire: https://tinyurl.com/99zp8ufh
Fuel line: https://tinyurl.com/bdff9bf3

nchattaway

Thanks Pat,
We didn't do a compression test when the tank was off. I'll have to get back to you on that. I'm very aware that because it has failed to start on me a number of times, I've only done 250km on the bike since bringing it out of storage. Someone suggested a few second gear runs up to redline and then shut the throttle no brakes, two or three times along a deserted stretch of "track". Because the carbs are gunked up, it doesn't like revving past 5000rpm easily and I ran out of track winding it near redline.

I'm not going to panic about the smoke yet.

giantkiller

Mine was in storage for about 11yeears only had 10,000 miles on it It smoked real bad for a while. And then went away. Had to clean the carbs multiple times. Mine had a full tank when put away. But was almost empty when I picked it up. Cleaned the tank several times. But still kept getting junk in the carbs. Still cleaning the carbs once in awhile. There are alot of little nooks and crannies in the tank. And every once in awhile something works loose. That's why I'm going to convert to a fuel pump so I can run a filter.
86 fj1350r
86 fj1380t turbo drag toy (soon)
87 fj1200 865 miles crashed for parts
89 fj1200 touring 2up
87 fzr1000 crashed
87 fzr750r Human Race teams world endurance champion
93 fzr600 Vance n hines ltd for sale
Custom chopper I built
Mini chopper I built for my daughter just like the big 1

oldktmdude

Quote from: nchattaway on December 19, 2015, 12:32:17 AM
Hmmm, I know someone with less cash than Fred who is probably going to need a good cylinder block with smooth bores and matching pistons. Er, it's me. Will the standard FJ1200 cylinder block bolt up as a replacement for a smoking FJ1100 motor? Is this the only difference between the FJ1100 and FJ1200 motors?

If the answers to my questions are "yes", then I'm wondering if you're looking to sell, Fred? I live in Australia, so freight could be an issue I guess.

Cheers,
Nathan
G'day Nathan, the answer to your question is yes. The 1200 block and pistons will bolt straight to the 1100 bottom end. Exhaust, carbs and head are also a direct bolt-on to the the 1200 block. With a little bit of work it will stay with a ZZR so putting some work into it will be worthwhile.
                                                                                                                                                                                           Regards, Pete.   :good2:
1985 FJ1100 x2 (1 sold)
2009 TDM 900
1980 Kawasaki Z1R Mk11 (sold and still regretting it)
1979 Kawasaki Z650 (sold)
1985 Suzuki GSXR 400 x2 (next project)
2001 KTM 520 exc (sold)
2004 GasGas Ec300
1981 Honda CB 900 F (sold)
1989 Kawasaki GPX 600 Adventure

aviationfred

Quote from: nchattaway on December 19, 2015, 12:32:17 AM


If the answers to my questions are "yes", then I'm wondering if you're looking to sell, Fred? I live in Australia, so freight could be an issue I guess.

Cheers,
Nathan


Nathan,
While running, the engine had plenty of power, the issue was oil consumption. A good number of members saw this bike in June at the Black Hills Rally, and can verify that it ran well, but had a definite oily exhaust smell.

I did mark the pistons as I removed them. The cylinder sleeves look to be in good shape. I would say, a very light honing of the cylinders and new rings would bring back a strong motor.

I can box up the cylinder block and pistons to get a shipping cost to Australia.


Fred
I'm not the fastest FJ rider, I am 'half-fast', the fastest slow guy....

Current
2023 Moto Morini X-Cape 650
2008 VFR800 RC46 Vtec
1996 VFR750 RC36/2
1990 FJ1200 (1297cc) Casper
1990 VFR750 RC36/1 Minnie
1989 FJ1200 Streetfighter
1985 VF500F RC31 Interceptor

oldktmdude

    Fred, I had an oil burning issue with a late model 1200 cylinder block. I installed new rings (after honing) and a set of valve stem seals but did not fix the problem. I sent the block to a machine shop, to get rebored and was later informed that the bores were out of round. I remember reading about Yamaha cutting costs back in the early '90s and were pressing the sleeves into the blocks and not reboring. Not sure how factual this is but it would account for the bores being oval. A measure of your bores might shed some light on your oil burning woes.
                               Regards, Pete. 
1985 FJ1100 x2 (1 sold)
2009 TDM 900
1980 Kawasaki Z1R Mk11 (sold and still regretting it)
1979 Kawasaki Z650 (sold)
1985 Suzuki GSXR 400 x2 (next project)
2001 KTM 520 exc (sold)
2004 GasGas Ec300
1981 Honda CB 900 F (sold)
1989 Kawasaki GPX 600 Adventure

ribbert

Nathan, if you are considering investing money into barrels you hope to use without a re-bore, it would be prudent to have them measured first.

Ovality and taper are normal wear characteristics but it needs to be determined if they are still within serviceable limits, needing only a hone. The measuring should be done by someone who not only knows how to measure, but knows how to interpret the readings. A local automotive machine shop would probably do this for free (if they thought they might get work our of it) or for a nominal fee.

It would be a wise investment before committing to freight and/or purchase costs.

Noel
"Tell a wise man something he doesn't know and he'll thank you, tell a fool something he doesn't know and he'll abuse you"

nchattaway

Thanks Noel,

That is good advice, but I'm not sure how I'd go about that from Australia when Fred has the parts in the US. I don't want to hijack Fred's project writeup, so will take this into PM land.

aviationfred

Received the slotted cam sprockets today..... Now it's time to get things in motion to put the motor back together.


I'm not the fastest FJ rider, I am 'half-fast', the fastest slow guy....

Current
2023 Moto Morini X-Cape 650
2008 VFR800 RC46 Vtec
1996 VFR750 RC36/2
1990 FJ1200 (1297cc) Casper
1990 VFR750 RC36/1 Minnie
1989 FJ1200 Streetfighter
1985 VF500F RC31 Interceptor

racerrad8

Quote from: aviationfred on December 23, 2015, 08:33:23 PM
Received the slotted cam sprockets today..... Now it's time to get things in motion to put the motor back together.

Fred,

Look at the teeth very closely. We had some trouble with tooth wear on some of the unbranded gears like those in your photo.

If they were stamped Falicon or APE then you are for sure good to go.

APE quit making them and as far as I know Falicon is the only factory manufactured sprocket on the market that I am aware of.

Randy - RPM
Randy - RPM