North American Fj1200's new Aussie life

[ribbert]

.....I found a small screw sitting beside the front wheel on the RHS of the bike.

Troy, you got lucky.



This is an accurate representation of what usually happens.

Noel

[FJmonkey]

I think that pie chart is missing a thin slice. It rolls to the most inaccessible location. However, the chart is quite accurate.

[Troyskie]

.....I found a small screw sitting beside the front wheel on the RHS of the bike.

Troy, you got lucky.



This is an accurate representation of what usually happens.

Noel

[Troyskie]

Well Mark, you were spot on with what it was and where it goes.

I had a few moments of confusion as there is a screw in place.

My guess of what has happened is the screw came out during some PO maintenance. Now we reference the pie chart from Noel. It teleported away from the PO onto my bike hoist, probably a decade into the future. The poor bugger put another screw into the position. Not a neat job, but functional. The screw is now tagged and ready to sit in the cupboard for the next 30 years. I assume it has been rattling round the bike till I stripped her down for the open heart.

So some progress last night. The throttle is now good and seems to be working as it should, choke too.

The rear shock is back in and ready for some of the rear-end accessory plastic bits.

I'm really impressed with how easy it is to remove and re-install the rear shock. Nice work Yamaha.

Hopefully this weekend I'll get some more done. I'll do some progress shots for proof.

[Troyskie]

Yummy is sleeping, having a nice dream of a new petcock.....

READY!!

Just wish I didn't have to go away for work for a week when the last, final, completing parts are due tomorrow!!!!!!!!!!

[FJools]

Troy,

you will be back before you know it.............The way my progress is going I should have the engine back in next weekend 

[Troyskie]

True Jools.

I did get a case of the impatients and threw the 1100 tank on to check for leaks. All good, so I threw on the side covers, and seat, grabbed the family and said 'watch this!'

Just need the petcock and a new rear disc for the FZR wheel and I am ready to roll.

[Troyskie]

Almost done!!!

Yummy is back together, new petcock, pods, rear disc, pads.

It only took half an hour to put it all together.

She flashed up beautifully, hardly any choke.

She just needs one more part, a new rear tyre for the blue slip.

One niggly little thing that popped up, the front RH indicator is on full time. It also comes on when the steering lock is set to 'park' when the tail light comes on. It flashes ok, but stays on when the ignition (headlight is hard wired) is switched on. Should I pull the fairing off and look for crossed wires? I know the one of the PO's had spent some time fooling with the wiring & didn't want to open that can-o-wrigglies just yet. I didn't do much to the wiring, just used some contact cleaner on the connections and plugged everything back as it was (I think).

Overall, WOW, at the tail end of the job, everything now seems like it was soooo easy, but...... I'd never done a clutch before, I'd never pulled a head and barrels down before. I'd never installed rings, cams, all the bloody gaskets, pistons, machined rear-wheels, swapped front-ends, or dropped a bike off a F-ing hoist for that matter.

I'm pretty certain the most I'd ever really done was pop the fairing, change the oil, possibly a chain or two. I don't even wash them much.

NOW? I'm ready for the hard bits, carbies, gearbox and electrics.

Yummy is now a 1219 with 91 front end, 17" front & back, option 1 modded clutch, rattle free fairing, and repaired fuel lines.

Once I find out what the issue is with the indicator I'll get her registered ready for Pete's in November (or put the 1100 side covers and number plate on  ).

Went for a test ride, rear shock is waaaaaaaaay out of adjustment, fixed. Rear brake needs bleeding. Front RH indicator cross wiring needs investigation. All other items AWESOME!!!!!!

LONG LIVE THE MIGHTY FJ!!!!!!!!!

[ribbert]

That's excellent news Troy, you may well have missed your true calling. Any more success and we'll have to get you a bigger helmet. 

As I've always said, the feeling of doing all that yourself is without equal and will make that bike the sweetest ride you ever had.

Roll on Bermagui.

Noel

[Troyskie]

Thanks Noel,

I did mean to say now at the end of the job it seemed easy, but the reality was everything was assembled wrong at least twice, sometimes three times. 

The amazing part is the bike started at all! Plus the rear wheel worked perfectly, and the clutch is perfect as well! I'm not known amongst my friends as the most 'handy' person (despite a shed full of tools).

The one reason why someone with my Neanderthal tool skills was able to get this project this far is this forum. Thanks for all the help and advice and support fellas, especially Pete. 

[FJools]

Troy
You may find this light problem is linked to it being a North American model.
My father in law has a US import kwaka Spectre 1100 in NZ which from memory has the indicators on all the time turning the L or R side off to flash. 
I think you need to study the circuit diagrams especially if someone has already been messing with it. You

[aviationfred]

For the US models, the 1989 and later models have the front turn signals lit when the ignition switch is in the on position. According to the 1986/1987 United States model wiring diagram, the front turn signals should use a single filament bulb and is only used as a flasher.

If the bulb is on all the time, you have a short somewhere in the circuit.


Fred

[Sparky84]

Troy by the sound of it you have done a marvelous job and taking us along for the ride also, I will miss your write-ups.
There is nothing better than breathing life into project like that and You did it all by yourself with guidance from Pete, but it was all You, very satisfying.

When I'd buy wrecks to fix and ride I had a mate just like Pete, he'd say wait until I'm there before you start pulling it apart but by the time he got there it was in bits.

When is your next project starting?, I can't wait for that ride

Cheers Alan

[Troyskie]

Woo hoo!!!

Jools & Fred, you were both right. All the wiring diagrammes I can find are for Aussie and UK models, not US.

I had a look through the files section and couldn't find a diagramme for the US models. I think I was after a one for California as it had the charcoal cannisters removed by a PO. I did see some wiring diagrammes on the forum for US models but cannot find them.

Long story short, all the diagrammes show two wires into the indicators. Mine had three. The colour coding for two of the wires was correct (phew!).

The third wire is a mystery & I'm not The Famous 5, I can't solve mysteries much beyond a crossword. It was coloured blue with a red stripe.

I checked the rear indicators and they are wired as per the diagrammes I have, so, after thinking about it....snip! On with the ignition, .... no more lit RH globe, but head light on as normal......flick the RH indicator switch.....WOO HOOOOOOOOO, it works. 
My daughter & I literally skipped back to the house to announce the good news.

PHEW!!!!!!!! At least on the snip I decided to cut the wire a fair way away from the connector so I could at least re-join if I had to, but WOO HOO!

I now believe all my contact cleaning may have uncovered an intentional blocking of the mystery wire by a PO to get rid of the front indicators being permanently on. It is possible I missed the LHS.

I am now ready for the blue slip! All I need is to change the rear tyre and I am done, done done!!!!!

You know, the only thing I might want to do now is get an Aussie switch block from the wreckers with a headlight switch so the headlight doesn't come on every I turn on the ignition.

Al, thanks for the words mate. Rest assured I have no intention of remaining silent after this, I have PLENTY more to learn, plus mate, the Shire is a nice ride away and Bermagui is only a couple of months away!

[ct7088]

I think the blue w red stripe wire is a marker light the bulb should be a dual element.