What did you do to your bike today?

[carsick]

Bryan, you do some nice work. Keep it up and keep the pictures coming too!

[DailyDriver]

A little bit of everything in this thread.

In the process of replacing my fork seals...again. Forks are disassembled on the workbench and I got all the parts cleaned up today.  Just waiting for two nylon piston rings from my dealer that go on each damper rod. Expensive! 

Also, working on a little patch job on the lower chin fairing. Got it cleaned and prepped for a little fiberglass work.

[Rob Vogel]

A little bit of everything in this thread.

In the process of replacing my fork seals...again. Forks are disassembled on the workbench and I got all the parts cleaned up today.  Just waiting for two nylon piston rings from my dealer that go on each damper rod. Expensive! 

Also, working on a little patch job on the lower chin fairing. Got it cleaned and prepped for a little fiberglass work.

You sounding like me. Also having to replace fork oil seal and do some fibre glass repairs on my mud guard. good luck and may the best man win...

[SkyFive]

I've been working at a feverish pace the last couple of weeks. I'm getting garage fever, it's something like cabin fever only worse. Let's see; I've rewrapped the wiring harness, repainted and rebuilt the calipers, mounted the rear subframe and most of the related parts, got all the electrical hooked up and checked out (checks good), bled the brakes and clutch and yesterday I spent three hours wrestling with the exhaust, I won. I got the battery all charged up. took the spark plugs out, pulled the upper oil galley plug and cranked the engine over until I had oil to the top end, I put the spark plugs back in, mounted the fuel tank, set the enricher, hit the start button and she roared to life. I didn't have time to take pictures or make a video but, now I'm in high gear to get the final adjustments made and the body work back on. I can't wait to ride!

[Flying Scotsman]

Git er done 

[paulfj03]

Looks nice Scott,

Crisp and clean and no caffiene!

[paulfj03]

Jeeez! make that sky five!!!!     

[rktmanfj]

Looks nice Scott,

Crisp and clean and no caffiene!

Jeeez! make that sky five!!!!     

Try some caffeine, Paul... it'll be okay.         


Randy T           
Indy               

[Mark Olson]

looks good

[SkyFive]

Thanks guys! I finally got it all back together, I kind of rushed towards the end after I heard the engine run, I just wanted to ride after that. My work is not finished though.. The first thing it did was bog down as I tried to accelerate. I hit the enricher and it picked up and went on. It will not accelerate from ~1000 to 3000 rpms unless I enrich it. It idles good though.

What I did; Rebuilt the carbs with Keyster KY-0560 86-87 FJ1200 kits (all of the jets, needles, float needles/seats, gaskets o-rings are new), I did reuse the original emulsion tubes because I have flat bottom slides and the FJ1200 emulsion tubes have a flange on top where my FJ1100 tubes did not. I set the floats at 22.5-23mm with a digital caliper, pre-synced the carbs with a feeler guage, set the mixtures at 2.5 turns, the needles are set to the middle and checked the fuel level in the bowls with clear tubing. The fuel level is about 10mm below the top edge of the float bowl, at the rear, with the carbs held at approx. 30° like they would be mounted on the bike. I marked each bowl with a Sharpie marker and they were all identical. I installed new fuel lines but a have since reinstalled the old fuel line thinking the fuel line may be kinking, it's not. I checked fuel flow at the petcock, it is good, I pulled the petcock and cleaned the screen anyhow but it wasn't very dirty at all. I filled the tank with fuel, no improvement. By now you've probably guessed it, I'm really dreading pulling those carbs back off, the airbox is a bbiittcchh!
I've pulled the spark plugs twice after a 5 mile ride, they are new, the #1 and #4 look like new with only a slight tint of combustion, the #2 and #3 look just about right, a little bit of black and a little bit of gray all around. I haven't checked for vacum leaks but I did replace the intake boots o-rings and they fit flush and secure. The #1 and #4 vacum ports are blocked off, the CDI hose is connected to #2 and the fuel petcock vacum is connected to #3.

Suggestions are warmly accepted and appreciated especially if it saves me from having to pull that airbox back off?

Anyhow, here are some pictures I took just a few minutes ago. I want to thank Doug (carsick) for sending me the original chrome bolts for the exhaust and engine at his own expense.    Marsh, I haven't forgot you, just as soon as I recooperate financially there will be a donation. Thanks for providing us with this website.

[rktmanfj]

Do you know the trick of removing the top subframe bolts and pivoting it down a bit?

Makes the airbox removal a bit less of a bitch.    

Oh, and very nice work, it looks great!

Randy T
Indy

[Flying Scotsman]

Looks awesome that puppys clean.

[SlowOldGuy]

>>>>>>>>>>>>>>>>>
The fuel level is about 10mm below the top edge of the float bowl, at the rear, with the carbs held at approx. 30° like they would be mounted on the bike.
>>>>>>>>>>>>>>>>>>>>

I don't think there is a 30 degree tilt to the carbs.  Measure the fuel level on teh side of the bowl in the middle and you'll always get the same reading.  I don't know how to interpret your fuel level the way you've measured it.  If too low, the idle jet could be sucking air.

I also don't know what your talking about with the slides and emulsion tubes.  All FJ slides are the same.  The shrouded emulsion tubes are preferred.

Don't assume that when you add choke and it runs better that you're too lean.  The choke circuit delivers a fuel/air mixture.  If the orifices on the float bowls are clogged, then you're dumping in lots of extra air.

I'm also not familiar with the aftermarket carb components.  I've read of lots of trouble from people that tried a/m carb parts.

DavidR.

DavidR.

[SkyFive]

Thanks. I do want to correct one thing on the loat bowl fuel level. I checked it with the carbs mounted on the engine. I summized that if I drew a straight line from the fuel level as measured from the rear, to the front of the carb bowl that the fuel level would be very nearly at the top of the bowl in the front.

I've done some reading and some thinkin' and I have two more things to try before I remove the carbs from the engine. I'm going to change the needles back to the original needles and then they will match the emulsion tubes. The reason for this is because when I changed the emulsion tubes I laid my originals beside the new (shrouded) emulsion tubes and the shrouded ones were longer and that was not including the shrouded portion. I'm thinking, longer emulsion tubes probably means the needles have a different profile and may be longer. The symptoms I'm having are in the needle circuit, the bike idles good. Secondly, I routed my vent tubes behind the engine and loosely wire tied them in a group, I read that if the vents are blocked the bowls may not fill completely.

I'm thinking the needles are the problem.

[doright1]

Very nice!  Good looking bike.