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Author Topic: 1993 ABS reccommissioning  (Read 25033 times)
JPaganel
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« on: June 30, 2016, 02:51:41 AM »

So, I took the first brief look into the innurds of the new to me 1993.

This looks to be a former enthusiast's bike that has fallen on hard times. Corbin seat and bags point to that, as well as the relay mod. I'm not sure yet if it's for headlight, coils, or both, but there is a pair of relays under the front fairing wired to the battery.

First things:

Top of engine is way crusty. Oil leak must have been around a good long time.
Battery is completely dead.
The PO story of carb cleaning and rebuild by a mechanic friend is questionable. Throttle does not move, looks like carbs are stuck, and the choke is sticky.
Clutch flops with no pressure whatsoever. I am going to look at a new MC and hose, and I have a slave cylinder seal kit ready.
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1993 FJ1200 ABS

1984 FJ600, up on blocks

1986 FJ1200, flaming wreck, repaired and sold
1986 FJ1200, repaired, ridden, sold


I don't want a pickle
I just want to ride my motorcicle
Steve_in_Florida
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« Reply #1 on: June 30, 2016, 06:40:06 AM »


Your new acquisition looks like a good platform to start from.

I look forward to your posts, as I'm refurbishing a couple myself.

Steve
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`90 FJ-1200
`92 FJ-1200

IBA # 54823
JPaganel
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« Reply #2 on: June 30, 2016, 02:18:27 PM »

Well, no question as to why the clutch circuit is bone dry...

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1993 FJ1200 ABS

1984 FJ600, up on blocks

1986 FJ1200, flaming wreck, repaired and sold
1986 FJ1200, repaired, ridden, sold


I don't want a pickle
I just want to ride my motorcicle
JPaganel
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« Reply #3 on: June 30, 2016, 04:50:28 PM »

New hoses next to the original 1992 vintage hoses.

Figured, if I'm doing this, might as well do it right.



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1993 FJ1200 ABS

1984 FJ600, up on blocks

1986 FJ1200, flaming wreck, repaired and sold
1986 FJ1200, repaired, ridden, sold


I don't want a pickle
I just want to ride my motorcicle
Pat Conlon
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« Reply #4 on: June 30, 2016, 05:25:08 PM »

Atta boy good
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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
wirehairs
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« Reply #5 on: July 01, 2016, 08:49:53 AM »

You were smart to get blue lines.  I've figured out that the plastic in the clear ones will always yellow in time (like the ones I bought!   ireful ); colored ones will look better over time.
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Tuneforkfreak
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« Reply #6 on: July 04, 2016, 10:30:08 AM »

I think it would be cool to have a project like this progress in video form on you tube. I'd watch that like a TV show. Looking forward to seeing your progress, was the fairing missing or rotted off from the slave leaking on it for so long? That looks like its been shitty for a good while.
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Yamahas from my past,
 IT465, IT200, YZ80. 350Warrior, Kodiak400, Kodiak450,
Various others include
XR600, KX500, KDX200, ATC250R, ATC350X, ATC 200S
Currently ride
FJ 1200 , DRZ400, Yamaha Viking, Suzuki Samurai dirt mobile
JPaganel
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« Reply #7 on: July 04, 2016, 01:43:14 PM »

I think it would be cool to have a project like this progress in video form on you tube. I'd watch that like a TV show. Looking forward to seeing your progress, was the fairing missing or rotted off from the slave leaking on it for so long? That looks like its been shitty for a good while.
Fairing was not on the bike. I think it's in one of the bags. I haven't really looked at it.

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1993 FJ1200 ABS

1984 FJ600, up on blocks

1986 FJ1200, flaming wreck, repaired and sold
1986 FJ1200, repaired, ridden, sold


I don't want a pickle
I just want to ride my motorcicle
JPaganel
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« Reply #8 on: July 04, 2016, 10:23:44 PM »

Today was washing day.

There was some serious crusticity here.





So, after some soap and brush it turned out the engine isn't actually black...





Although, by the feel here I probably should replace the clutch rod seal

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1993 FJ1200 ABS

1984 FJ600, up on blocks

1986 FJ1200, flaming wreck, repaired and sold
1986 FJ1200, repaired, ridden, sold


I don't want a pickle
I just want to ride my motorcicle
TexasDave
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« Reply #9 on: July 04, 2016, 11:31:22 PM »

Looks like you need some valve cover bolt gaskets also. Nice work so far.  Dave
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Tuneforkfreak
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« Reply #10 on: July 05, 2016, 07:59:31 AM »

Eww that clutch rod seal looks a little outdated.
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Yamahas from my past,
 IT465, IT200, YZ80. 350Warrior, Kodiak400, Kodiak450,
Various others include
XR600, KX500, KDX200, ATC250R, ATC350X, ATC 200S
Currently ride
FJ 1200 , DRZ400, Yamaha Viking, Suzuki Samurai dirt mobile
JPaganel
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« Reply #11 on: July 05, 2016, 08:35:23 AM »

Looks like you need some valve cover bolt gaskets also. Nice work so far.  Dave
Already have the bolt seals. Gasket is en route.

Eww that clutch rod seal looks a little outdated.
Yeah, feels a little loose, too.
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1993 FJ1200 ABS

1984 FJ600, up on blocks

1986 FJ1200, flaming wreck, repaired and sold
1986 FJ1200, repaired, ridden, sold


I don't want a pickle
I just want to ride my motorcicle
JPaganel
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Location: Minnesnowta, USA
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« Reply #12 on: July 05, 2016, 11:20:17 PM »

The slave cylinder is not inspiring confidence.

The bore is porous. I don't know that I can buff it out to where it won't leak.



Mulling over getting a new one from Randy.
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1993 FJ1200 ABS

1984 FJ600, up on blocks

1986 FJ1200, flaming wreck, repaired and sold
1986 FJ1200, repaired, ridden, sold


I don't want a pickle
I just want to ride my motorcicle
ribbert
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« Reply #13 on: July 06, 2016, 01:47:03 AM »

The slave cylinder is not inspiring confidence.

The bore is porous. I don't know that I can buff it out to where it won't leak.

Mulling over getting a new one from Randy.

Get a new one, you'll be chasing your tail trying to make something of that.


Safety notice to no one in particular. Experienced tradesmen, even knowing every shortcut, tip and trick, will never use anything on a hydraulic cylinder other than a proper tool. Knowing how to use it helps too. The most they might do by hand is "wipe" it with a bit of emery, but that's it.
Some of the "cleanup" and "servicing" methods described here from time to time would make them cringe, especially on brake components.

It is also good practice to never re install cups once removed (such as for "servicing"). Over time they become mated to the bore which is something you can't match when re installing them. Probably won't fail but certainly won't last as long.

Noel
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ribbert
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« Reply #14 on: July 06, 2016, 03:09:49 AM »

.....IMO

Noel
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