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Author Topic: Bryan's 1989 FJ1200 rebirth in Poplar Grove, IL  (Read 46354 times)
Waiex191
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« Reply #120 on: June 26, 2020, 10:44:12 PM »

First diaphragm going back in.


First carb together.  You can see my nifty RPM allens on the diaphragm cover, holding on the bowl, and holding down the float valve seat.


Whoops - wasn't keeping track of the front vs the back of the carb.


Here are all 4 carbs together.  Next session it will be time to gang them.


And in case you missed my post above, and have a helpful answer:
All of my floats have measured about 20.6 mm before I adjusted anything.  Old floats, seats and new needles.  Seems odd I have to adjust them so much.  Am I just being paranoid?  I have read all the carb files and am checking with the carb bodies about 70 degrees, so the float is not pressing down on the spring.  Definitely not the first floats I've adjusted.  I'm using my calipers set for 22.3mm.
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Bryan
1989 FJ1200
1981 Suzuki GN400
Poplar Grove, IL
 
Waiex191
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« Reply #121 on: June 27, 2020, 06:07:42 PM »

My carbs are now ganged together.


I used a .030" piece of MIG wire as a feeler gauge to bench synch them.


Now I really need to pop off that heat shield and clean. 

How critical is it to replace my manifold o-rings if I don't remove them?
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Bryan
1989 FJ1200
1981 Suzuki GN400
Poplar Grove, IL
 
Pat Conlon
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« Reply #122 on: June 27, 2020, 11:05:23 PM »

It would be a shame to have a partial vacuum leak from a dried out hardened O ring.
Those are the kind of things that drive you nuts when you are tuning your carbs.
You’ve come this far....pull those manifolds off, check them out.
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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
Waiex191
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« Reply #123 on: June 28, 2020, 01:50:33 PM »

Thanks Pat, good advice.

My FJ project just got a major boost.  I was trying to pull off the GN400 exhaust pipe to track down an oil leak. Busted the bolts. This task has spiraled down to a broken ez-out in the head.

DOOM

I think my short path back to riding is to finish the FJ1200.
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Bryan
1989 FJ1200
1981 Suzuki GN400
Poplar Grove, IL
 
fj1289
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« Reply #124 on: June 28, 2020, 03:39:59 PM »

OUCH!

I have a cheap set of Not so “ez outs”.  I keep the left twist drill bits that come with the set and throw away the ridiculously brittle bolt extractors.   Never had the left twist bits fail to remove the broken bolt or stud. 

Then again, maybe time to eBay a GN400 head and have it shipped to a shop for a valve job and porting .....
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Waiex191
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« Reply #125 on: June 28, 2020, 04:11:03 PM »

OUCH!

I have a cheap set of Not so “ez outs”.  I keep the left twist drill bits that come with the set and throw away the ridiculously brittle bolt extractors.   Never had the left twist bits fail to remove the broken bolt or stud.  

Then again, maybe time to eBay a GN400 head and have it shipped to a shop for a valve job and porting .....

I bought a GN parts bike for cheap years ago.  That head is my backup plan.

Working on the FJ. Heat shield is off and manifolds are coming off.  Pictures later.  Dean will be jealous how clean my top end is now.
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Bryan
1989 FJ1200
1981 Suzuki GN400
Poplar Grove, IL
 
Waiex191
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« Reply #126 on: June 28, 2020, 05:33:52 PM »

Heat shield off. I didn't break any of the rubber parts. 


With the shield off, I cleaned up. You can see it's much cleaner than Dean's from Rugby. *


Intake ports.  My new o-rings are installed.


My checklist for completing the project.






* This is a lie
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Bryan
1989 FJ1200
1981 Suzuki GN400
Poplar Grove, IL
 
Millietant
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« Reply #127 on: June 28, 2020, 06:03:24 PM »

Looks like a twin sister, Bryan     good2
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Dean

'89 FJ 1200 3CV - owned from new.
'89 FJ 1200 3CV - no engine, tank, seat....parts bike for the future.
'88 FJ 1200 3CV - became a race bike, no longer with us.
'86 FJ 1200 1TX - sold to my boss to finance the '89 3CV I still own.
Pat Conlon
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« Reply #128 on: June 28, 2020, 07:09:26 PM »

Good job....How do those rubber manifold boots look? Any deep cracks?
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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
Waiex191
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« Reply #129 on: June 28, 2020, 07:37:07 PM »

Looks like a twin sister, Bryan     good2
You did read my footnote I hope!

Good job....How do those rubber manifold boots look? Any deep cracks?
They looked new ish to me. No cracks and the rubber was pliable.  Way nicer than my '81 GN400.
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Bryan
1989 FJ1200
1981 Suzuki GN400
Poplar Grove, IL
 
Millietant
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« Reply #130 on: June 29, 2020, 01:18:13 AM »

Yes - Twins, but not identical twins  sarcastic

She's looking a lot better than she was. though  good2
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Dean

'89 FJ 1200 3CV - owned from new.
'89 FJ 1200 3CV - no engine, tank, seat....parts bike for the future.
'88 FJ 1200 3CV - became a race bike, no longer with us.
'86 FJ 1200 1TX - sold to my boss to finance the '89 3CV I still own.
ribbert
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Melbourne (Aus.)


« Reply #131 on: June 29, 2020, 08:59:11 AM »

OUCH!

I have a cheap set of Not so “ez outs”.  I keep the left twist drill bits that come with the set and throw away the ridiculously brittle bolt extractors.   Never had the left twist bits fail to remove the broken bolt or stud. 

Then again, maybe time to eBay a GN400 head and have it shipped to a shop for a valve job and porting .....

Those spiral tapered extractors that seemed to find their way into everyone's tool box should be banned. The tapered shape puts all the load on one part, which is where it breaks. They work if the the broken bolt is no longer tight once the heads broken off but if the remainder of the bolt is stuck, DON'T use them.

I favour these (on the left) because of their uniform shape but increasingly find Torx bits (on the right) to be excellent and the hammer blows driving them in assists greatly in loosening the bolt:



Noel

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"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”
fj1289
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« Reply #132 on: June 29, 2020, 09:07:35 AM »

Hadn’t thought of using a torx bit!  Will have to give that a try if the left twist drill bits don’t get it done first
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Waiex191
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« Reply #133 on: June 29, 2020, 11:55:17 AM »

Hoses on:


Carbs installed and ready to go:


A short video of the throttle & choke working:
https://youtu.be/JvKZ6gD0SAU
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Bryan
1989 FJ1200
1981 Suzuki GN400
Poplar Grove, IL
 
Waiex191
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« Reply #134 on: June 29, 2020, 12:43:58 PM »

Some spammer put a link in my comments and I couldn't figure out how to delete it, so I deleted the whole video.  It's now unlisted.
https://youtu.be/Dvm0MY04huc
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Bryan
1989 FJ1200
1981 Suzuki GN400
Poplar Grove, IL
 
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