Squids toy take 2

[squidley63]

I had a thread going for my 89 fj1200 from a few years ago but I managed to lose access to the pictures of what I had done so far. Over the last 6 years I've only managed to get a couple of riding seasons in with my bike. It's been plagued by carburetor problems and wiring issues that I just didn't get ahead of.  Now that I have a building to work in I'm going to try and get the fj back to its old self.

This pic is how my fj looked when I bought it. Since then I've replaced the rusted gas tank with a fj1100 tank I got off eBay. I've also changed out the fairing with an uncut one I picked up from a member of the forum.

Attached is a pic of my bike sitting in the shed waiting for me to make it all better.

[Pat Conlon]

Welcome back laddie! Looking forward to your resto...
Judging by your seat, looks like your bike had some company so, closely check all your wires and your air box.

[squidley63]

Seat is just dry rotted from sitting in the weather. The weather has done a lot of havoc to the wiring. I found a lot of connectors and wires that have seen better days. Gotta love old bikes.

[squidley63]

This relay plate was added a couple of years ago to keep the coils powered up and the headlights on. Didn't help keep the fuel pump running though which almost stranded me on the side of the road.

[squidley63]

Had a few hours today to get some tinkering done with the bike. I pulled the tank off and emptied out the stuff that used to be gas out of it. Pulled the sender and petcock off to get it cleaned outa bit better. Going to scuff up the paint on the tank and get a better coat of paint on it as it is chipping off in places. Maybe try to find a paint that could blend with my fairings.

I also pulled the start switch off to try and get it working better as it kept trying to stick in.

[aviationfred]

I am curious on how well the vacuum diaphragm petcock will work with the fuel pump. Will they play nice together??



Fred

[Motofun]

I also pulled the start switch off to try and get it working better as it kept trying to stick in.

The stock spring in the start switch is a weak part.  I've had 2 or 3 fail over the years.  AI don't recall what I did to fix it....perhaps this would be a good item for a robust fix?

[squidley63]

I run the petcock in the prime position and put on position to stop flow when it sits. I have found it's pretty easy to reach the petcock when the motor cools a bit.  Also I have a fuel pump that stops flow pretty well to keep the carbs from flooding out.

I have thought of wiring in a push button setup for start without a pivot involved. I've seen a few marine buttons that might work ok with the solenoid. I still have some fiddling to do to see what i can make work.

I did get the switch to stop stocking in at least for now.

[squidley63]

Haven't had too much time to work on the bike lately but I did get the start switch cleaned and working ok for now at least. I also have spent some time stripping the paint off the tank as it has some peeling between the clear coat and the color. Also had some bondo flaking issues. I'm taking it basically to bare metal for a better foundation for paint.

I've also did some work on the wiring replacing some high resistance wires in the loom between the fuses and the control boxes.  I'm debating on how much of the wiring to pull out and replace while I'm at it.  Going to do a bunch of voltage drop checks at various points to ensure reliablility in the future.

[squidley63]

Had the last 2 days off and managed to make some headway on the fj. I finished up the paint removal and rust cleanup on the tank yesterday and started the painting. I put on 4 builduplayers of primer and sanded out some bad spots followed by some more primer before starting the color. I went with black paint for the time being at least to keep the rust off it.

I also started to address my front brake master cylinder issue by replacing it with a master and calipers from an r1. I pulled the old master and calipersoff and mounted the new to me parts. Going to flush the stock lines and get things hooked back up and bled.

I'm still spending time between coats working on the wiring harness. Trying to get all the connections cleaned up and suspect wires replaced.

[Pat Conlon]

....Going to flush the stock lines and get things hooked back up and bled. ...

Stock lines? As in, 30 year old rubber brake lines? Really?

[Millietant]

Negates the effect of the R1 master cyl and calipers !!!!

C'mon Squidley, do it properly......can't scrimp on your brakes 

[ZOA NOM]

Do this.