Repair of the Christmas roasted FJ

[T Legg]

I've been using a blow dryer to soften up my intake boots before installing my carbs.It works well with old stiff boots.

[Tuned forks]

Fred, you   bought   NEW   carburetors?  The old ones were not rebuildable?  They sure look pretty.

Joe

[aviationfred]

you   bought   NEW   carburetors?  The old ones were not rebuildable? 

Joe

Yes, I bought brand new carbs. The pre tuned by RPM versions. The old carbs were damaged beyond repair. A combination of, the Fire and Previous owners ham fisted attacks (maintenance) on the carbs

From the very first tank of fuel when I purchased this bike, I noticed fuel consumption was bad, and much more than even my FJ1300. A few other small things were noticed over the year of ownership that had me questioning the operation of the carbs. Randy confirmed this when he disassembled the carbs.

Fred

[RPM - Robert]

I wouldn't say "beyond" repair, but the cost of parts to repair them properly would have been almost equivalent to a new set. If new sets were no longer available. In all likelihood these burned up ones could have been repaired with no problems, along with the problems from previous maintenance. Looks like Fred will be back on the road in no time now.  

[Pat Conlon]

Fred, did you put fresh valve bolt cover grommets in? I wonder if the old ones hardened with the heat.

Fine job laddie! You'll be riding this weekend

[aviationfred]

Fred, did you put fresh valve bolt cover grommets in? I wonder if the old ones hardened with the heat.

Fine job laddie! You'll be riding this weekend

They don't appear to have any damage. I will monitor them for leaks after I get the bike up and running.

Fred

[aviationfred]

The ignition switch connector got a bit melted so it needs changed. The New throttle cables have been installed and everything has been tidyed up. I did get a new fuel line from O'Reilly's. New petcock and fuel filter installed.

Fred

[aviationfred]

All ready to put fuel in the tank and check for leaks. Primed the carbs and no leaks.   the bike fired up with some coaxing of added throttle. The idle adjustment was way way low. Made the appropriate adjustment and I have a running FJ again.    


Hopefully the video will post.

https://youtu.be/lUPPEr5UBbE

Fred

[Tuned forks]

Fred, because of your work experience, do you use electrical connectors that are aviation rated?  I wonder if you don't like the 3M Weatherpack connectors?

Joe

[ZOA NOM]

This is turning out to be a hell of a good save, Fred.

[Firehawk068]

Nice work Fred!

[aviationfred]

Fred, because of your work experience, do you use electrical connectors that are aviation rated?  I wonder if you don't like the 3M Weatherpack connectors?

Joe

I have tried using some actual aircraft connectors and splices. The connectors that are weather proof typical are metal and fairly bulky. The splices have a drawback as they are designed for use with Teflon insulated wires. The insulation is very thin walled and have a very high heat resistance. The problem with motorcycle wires is... The insulation is thicker and not heat resistant at all. To use the environmental splices, the heat shrinkable sleeve barely fits over the insulation and the FJ wires have a tendency to melt and/or char trying to get the sleeves to shrink properly.

I have had great success with the Molex style connectors. They are not much different from most of the FJ connectors.


Fred

[Troyskie]

Nice work on the repairs Fred.

Troyskie

[aviationfred]

A late post..... I got about 100 miles on the bike Sunday and it performed flawlessly. Can't wait for Rally season. Bring on the WCR.

Fred

[andyoutandabout]

Hence forth this shall be the standard by which teal stripers are judged.
Nailed it on the rebuild.
Nice one Fred.