North American Fj1200's new Aussie life

[Pat Conlon]

FYI, there is a special tool made for removing those long studs.


http://racetoolz.com/

However, Noel is correct, if they are not stretched, leave them alone. The plastic coating on them (burned off) is not important.

[Troyskie]

Righto then, common wisdom rules, I'll leave them alone.

As I mentioned, I think they're ok. The corrosion appears to be superficial. I'm going to zinc rub the cleaned shaft to add some corrosion resistance to the substrate then BBQ black them to add a barrier coat. A gentle piano style flick on each (both good and corroded ones) sounds the same note, so I'm guessing there are no fractures or excess stress.

There are some cold gal paints that quote heat resistance up to 300C (572F). Does anyone have any idea how hot our motors actually get? If it's under 300 I'd rather cold gal them completely to increase corrosion resistance.

Another question, several of the dowel pins which collar the studs have corroded to nothing & are the source of the corrosion to begin with. Do I replace them?

Troy

[Pat Conlon]

The front part of the head gets the hottest. Exhaust Gas Temps (EGT) can reach 1200-1400*F

[FJmonkey]

The front part of the head gets the hottest. Exhaust Gas Temps (EGT) can reach 1200-1400*F

The temps are a bit steep for Alum, alloys can alter it a bit. https://www.google.com/webhp?sourceid=chrome-instant&ion=1&espv=2&ie=UTF-8#q=melting%20temp%20of%20aluminum

I would say less than 1200 F. But that assumes the gas is that hot and the air cooling keeps the metal under the melting point... Damn HOT!!! 

[Troyskie]

Whilst I'm busy sourcing parts I thought I'd crack on with some other bits whilst the kids were developing their iPosture .

As the rear shock is out getting a stiffer spring put in, thought I'd remove, or at least see how hard it is to remove the swingarm.

Super easy as it turns out. Mainly because there is nothing else attached, just a few easy to remove bolts. BUT  after some careful reading of my manual the bloody thing didn't want to move.

A couple of beers, a general tinker, re-read of the manual and, then a close look with a bright light. The answer is obvious to the rest of you who've done it, but now I know.

I've learnt to lift it up about 40mm, and then it clears the frame holding it.

I know this is simple, but this little step was totally missed in the manual & if you forced it straight out you'd do serious damage, perhaps even ruin half your bike.

Anyway, now I know how easy it is to remove the swingarm, I won't have any concerns in the future doing this. Many tedious jobs will now be heaps easier.

I just realised as I type this that the FZR wheel is due back this week, & with the swingarm out it will be much easier to check fit the caliper hanger mount narrowing and getting the calliper to centre on the disc.

I still hope I can get this all back together!!!

Next steps before I hopefully start putting Yummy back together will be:
Clutch fix, straight out of the forum with the larger fibre plate on the end. I'll be replacing the fibre plates and diaphragm spring while I'm there (thanks Randy).
Flush the crankcase.
Change some dodgey connectors on the wiring.
General clean-up as she's in bits.
Paint up what I can (I'm not doing the whole thing this time, perhaps next time).

Here's some pics of the weekends continued disassembly...I hope I can get this all back together!!! (I think I said that already  )

[Troyskie]

I double checked the pictures, they were righ :ireful:t way up 

[Troyskie]

Any suggestions about a chain buffer replacement? One of the PO's decided it wasn't necessary....Need a solution...

[aviationfred]

This place is in the U.S.. I have purchased used parts from them a few times with great results. Possibly send them an email about the swing arm guide in box number 75.

here is the direct link to the photo of Box 75

https://picasaweb.google.com/114333149059306462902/UsedParts?authkey=Gv1sRgCPrL0bzw-deBlgE&feat=flashalbum#5401134160083592434

Here is the link to Poway Motorcycles.

http://powaymotorcycle.com/SanDiego/

The only other options that I have thought of...... look on eBay for '84-'87 swing arms that come with the chain guide still attached and in good shape, or do a swap to a late model FJ, Thunder Ace, or FZ1/Fazer 1000 swing arm.

Fred

[Troyskie]

Thanks Fred. That gives me an idea. I think I'll try some wreckers to see what they may have.

[ct7088]

I bought a swing arm that had the chain guard but it wasn't whole after shipping. I used AC236B1/2 Sealant to stick it together and to the swing arm along with the one screw. The AC236 is doesn't get rock hard and sticks to most everything, only time will tell if it will hold.

Chris

[FJmonkey]

Aw Crap, I am feeling the need to reverse engineer another FJ part. The '86 swing arm is already off so all I need is to play hooky from work for a bit and figure out a proper and easy fix. I might need to sell this to Randy for an RMP exclusive product...

[Troyskie]

Some progress last night.

Did the clutch mod & replaced the narrow fibre. I must say, for someone as mechanically challenged as I am this seemed to go very smoothly, and quick, really, it only took about an hour. So anyone with a slippy clutch, do the mod. Tools required, socket set and a torque wrench.

Check measured the fibre plates and friction plates. Good as new, compared dims with the new ones, all very nice.

I did replace the diaphragm spring with a new one just in case, but it was measuring nicely and looking pretty good. I'll keep it for a spare. So I basically have a complete clutch set spare, woo hoo! More parts for the shed.

A bit of a fail with the FZR wheel. More machining required.

I'll now be taking 1.2mm off the sprocket side spacer and another 6 odd mm off the wheel on the sprocket side, plus same off the sprocket carrier. At this point I'll need to take away some of the hub outer and maintain the inner step.

Hopefully this will be completed this week and I can have the wheel on for the weekend.

Parts for the top end are now being ordered (1219 Wiseco is cheaper than 2nd oversize OEM!!), so possibly another month and I'll have Yummy purring (if I can put it all back together!!!!!! ).

I'm beginning to understand moditis. When the bike is in bits I may as well do the .....and the....

[Troyskie]

Lots o work meetings & stuff this week, so very little work on Yummy. Haven't even had the time to sort out some parts questions with the local shop/Randy.

Anyhoo, late yesterday picked up the FZR wheel from the local machine shop. A little stuff-up with the spacer that we'll sort next week, but    it fits very nicely. I'll test fit to double check chain alignment.

Now time for a little clean-up, paint, and new bearings & tyre.

The rest of the bike will begin getting some touch-up and paint after I give her a good clean. Clean process will be kero, then degrease and some rubbing back, then lots of tape for the paint.

Here's some pics of the wheel.

[oldktmdude]

   G'day Troy, if you need help with your choice of tyre, give me a call or PM. I've tried most of the latest and greatest in the 17" range.
Happy to help with advice on your selection. 
   Regards, Pete.

[Troyskie]

thanks Pete, I'll take you up on that.
Troyskie