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1993 ABS reccommissioning

Started by JPaganel, June 30, 2016, 03:51:41 AM

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JPaganel

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.
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


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
`90 FJ-1200
`92 FJ-1200

IBA # 54823

JPaganel

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

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

New hoses next to the original 1992 vintage hoses.

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



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

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

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.

Tuneforkfreak

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.
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

Quote from: Tuneforkfreak on July 04, 2016, 11:30:08 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.
Fairing was not on the bike. I think it's in one of the bags. I haven't really looked at it.

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

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

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

Looks like you need some valve cover bolt gaskets also. Nice work so far.  Dave
A pistol is like a parachute, if you need one and don't have one you will never need one again.

Tuneforkfreak

Eww that clutch rod seal looks a little outdated.
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

Quote from: TexasDave on July 05, 2016, 12:31:22 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.

Quote from: Tuneforkfreak on July 05, 2016, 08:59:31 AM
Eww that clutch rod seal looks a little outdated.
Yeah, feels a little loose, too.
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

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.
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

Quote from: JPaganel on July 06, 2016, 12:20:17 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
"Tell a wise man something he doesn't know and he'll thank you, tell a fool something he doesn't know and he'll abuse you"

ribbert

"Tell a wise man something he doesn't know and he'll thank you, tell a fool something he doesn't know and he'll abuse you"