1984 FJ 1100

[moelarrycurly]

Hello Everybody,

  I'm Jason, I'm an Aircraft Mechanic living in Columbus Ohio. I have been working on a basket case 84 FJ 1100 for about three years. I rode it for the first year and a half but parked it at 32k miles after low compression on all 4 cyl was discovered (60, 90, 110, 80 psi). I sent the head into my local machine shop for a once over and I discovered the cylinders had glazed. I can only guess this is from the abuse it suffered at the hands of the 20 something wannabe mechanic that I bought it from (he ruined the carburetors by trying to install a cobbled together jet kit). I bought a new set of carbs from RPM less than 2000 miles ago and they worked well-but the engine never developed real liter bike power or torque.

  After the bike was disassembled it sat for several months while I saved the funds for its restoration. Well the time has come...

I bought a 1297cc kit from Andrews Motorsports. I am EXTREMELY happy with the quality and packaging of this kit. I have the cylinders installed and ready to go. But when I got the head back from the machine shop-most of the paint on the head was gone. I want it to look stock-What kind of paint should I use? (due to budgetary restraints imposed by my wife, powder coating is out).

[FJmonkey]

Welcome Jason, happy to learn that one more FJ is being saved from the parts bin. To help answer your question, I don't think powder coating will last long on an engine head. The proper engine paint has been posted here so a little searching may be required. It is unique to other paints and requires heat to fully cure. So handling after paint and before curing can damage the finish (finger prints). Some have used the kitchen oven to cure the paint but they are most likely single (became single shortly after) or did it with the wife away. Getting a cheap used oven might be a good way to go, then sell it for what you paid for it. Post up on your progress and show us some pics.

[aviationfred]

Welcome to the forum  

I also used the Andrews Motorsports 1297cc kit for my engine. I did a complete write up here on the forum. Click on the blue link to see it. http://www.fjowners.com/index.php?topic=14834.0

I painted my lower cases with Rustoleum 500 degree gloss engine paint. The head on my bike has no paint at all (I like the look). The head gets a bit hotter and you may want to use 1500 degree BBQ grill paint.

I have about 2000 miles on the new pistons and the bike purrs like a kitten.

Fred

[PaulG]

What kind of paint should I use? (due to budgetary restraints imposed by my wife, powder coating is out).

You might want to look at this product.  They have engine enamels and barrell paints, etc.  I use their header paint for the headers and collector box and seems to work ok.  I usually repaint them every couple of years due to their direct exposure to the elements.  Don't know how well their other products work.  It's sold just about everywhere.  You can check it under the Retailers section.

http://www.vhtpaint.com/

Others may have better input on something they actually use.

[ribbert]

What kind of paint should I use? (due to budgetary restraints imposed by my wife, powder coating is out).

Yep, I also endorse VHT engine enamel, as would many other members. I'd be wary of non engine specific paints, they may handle the heat but can be affected by fuel and oil.

$15 a can and you'll only use about a quarter of it.

This members engine paint job is 60,000km and many years old.



Noel

[fjbiker84]

Have you checked out the transmission on the bike?  It's my understanding that if the bike was abused, the 84 was prone to start slipping out of 1st or 2nd gear.  Adding that much power could make the problem worse.  Look forward to pictures of the finished product.

[moelarrycurly]

engine is back together just getting the odds and ends done. Here a question... How far out of the case is the clutch pushrod supposed to protrude??? I'm trying to determine if the ball is in there or if its M.I.A.. I stuck a magnet in there and no ball came out. looking in the hole there appears to be one-but it might be the end of the smaller pushrod... My clutch slave cylinder was leaking and I think a missing ball might be why...

[moelarrycurly]

Welcome to the forum  

I also used the Andrews Motorsports 1297cc kit for my engine. I did a complete write up here on the forum. Click on the blue link to see it. http://www.fjowners.com/index.php?topic=14834.0

I painted my lower cases with Rustoleum 500 degree gloss engine paint. The head on my bike has no paint at all (I like the look). The head gets a bit hotter and you may want to use 1500 degree BBQ grill paint.

I have about 2000 miles on the new pistons and the bike purrs like a kitten.

Fred

I loved the write up!!! And the bike looks great!

[aviationfred]

engine is back together just getting the odds and ends done. Here a question... How far out of the case is the clutch pushrod supposed to protrude??? I'm trying to determine if the ball is in there or if its M.I.A.. I stuck a magnet in there and no ball came out. looking in the hole there appears to be one-but it might be the end of the smaller pushrod... My clutch slave cylinder was leaking and I think a missing ball might be why...

I am prepping the bike for a high mile ride and swapped my front sprocket to a 19 tooth. Since I had the sprocket cover and clutch slave off, I took a picture of the clutch push rod. I hope this helps.


Fred

[Bones]

engine is back together just getting the odds and ends done. Here a question... How far out of the case is the clutch pushrod supposed to protrude??? I'm trying to determine if the ball is in there or if its M.I.A.. I stuck a magnet in there and no ball came out. looking in the hole there appears to be one-but it might be the end of the smaller pushrod... My clutch slave cylinder was leaking and I think a missing ball might be why...

I am prepping the bike for a high mile ride and swapped my front sprocket to a 19 tooth. Since I had the sprocket cover and clutch slave off, I took a picture of the clutch push rod. I hope this helps.





Fred

19 tooth sprocket? I thought 18 tooth was the biggest you could get. Is that a special order Fred.

[aviationfred]

This is the sprocket I found on eBay. I installed it this evening and rode about 30 miles this evening. Not much difference than the 18 tooth as far as moving from a stop. My rpm's dropped about 500 at high way speeds.

I have about an 80 mile ride in the morning on the interstate. Speeds will be in the 75 to 80 MPH range. Estimated RPM's should be in the 4000 RPM range with the 19t front and a 38t rear on a GSXR750 17" wheel and a 180/55/17 tire.


http://www.ebay.com/itm/231949815336?_trksid=p2060353.m2749.l2649&ssPageName=STRK%3AMEBIDX%3AIT


Fred

[Pat Conlon]

That's interesting Fred.

If you go to the PBI Sprocket website, it lists the 18 tooth as the max size.
http://shop.pbisprockets.com/product.sc?productId=303&categoryId=-1

I wonder where they came from?

[racerrad8]

engine is back together just getting the odds and ends done. Here a question... How far out of the case is the clutch pushrod supposed to protrude???

The push rod should be approx 2" out of the engine. I have a couple of FJ rods with the grease build up onthem and that is the measurement.

If the ball is missing, subtract 5/16" (8mm) which would equal 1 11/16" of the rod sticking out of the engine.

Randy - RPM

[fj1289]

This is the sprocket I found on eBay. I installed it this evening and rode about 30 miles this evening. Not much difference than the 18 tooth as far as moving from a stop. My rpm's dropped about 500 at high way speeds.

I have about an 80 mile ride in the morning on the interstate. Speeds will be in the 75 to 80 MPH range. Estimated RPM's should be in the 4000 RPM range with the 19t front and a 38t rear on a GSXR750 17" wheel and a 180/55/17 tire.


http://www.ebay.com/itm/231949815336?_trksid=p2060353.m2749.l2649&ssPageName=STRK%3AMEBIDX%3AIT


Fred

I bought one of those too. Haven't fit it yet - its on the shelf with all the other gears for the Colorado Mile.   Look like there is still a lot of room with it installed -- thanks for the pics.

[moelarrycurly]

Fired up the FJ for the first time today. It sounds absolutely amazing. Got some odds and ends to do. I bought a new set of carbs from Randy a couple years ago, they're fj1200 carbs, so I'm converting to a fuel pump.

An issue that popped up.. I bought the APE head studs and nuts. The nuts are not capped like the originals. The nuts that cap off the oil galleys on the right side have oil leaking from the top-and it's a pretty good leak too. APE's website said nothing about sealant. Anybody have this issue??
Thanks,
Jason...