Back in 1989 I graduated school and started my first job. Between graduation and my start date, I rode a 1981 Suzuki GS650E from Connecticut to California and back. Got to see a bunch of the country. I intended to do some more long distance riding, plus with a paycheck I wanted to upgrade from my two '81 Suzukis. I also had a GN400, which I still have and ride. When I first sat on the FJ in the dealership, I knew I had the right bike. I had also considered a Hawk NT650. Very cool bike, but I could only afford one. I bought it with 75 miles on the clock from the dealer.
Fast forward a few years - now I'm married with two kids in diapers. I have a lot less time. I had stopped riding the GN400 because I needed to adjust the valves. Then the fuel pump or something died on the FJ, and I parked it - then never got around to fixing it until recently. I did get the GN going again a couple of years ago. My kids are out of diapers (thankfully) and my oldest just got a Magna 500 from a neighbor. It's time to get back in.
First I started taking the bike apart. Bodywork:

Here the carbs have been pulled off. Nice and easy with the perimeter frame.

Sitting since 2004 (the date I wrote on the last battery) was not good for the carbs. Everything had turned to glue. In trying to get the float pivots out, I managed to break a couple of pivot mounts. Also I stripped an emulsion tube. Not good. Here is the first pivot I broke:

At this point it was clear that I couldn't proceed with the carbs together. And, once you are truly screwed, you have nothing to lose. So I separated them.

To fix it, I drilled a couple of .040" holes and safety wired the broken piece back on.


Then I broke another one. This pin was really stuck. You can see I've bent the pin as well.

With the bent pin, I had to dremel off the other side so I could remove the float.

I safety wired this one back on too. Curious what the peanut gallery thinks of this repair, or if there are any other ideas out there.


I mentioned I stripped an emulsion tube. That sucker was really glued in place. Try 2: I ground a screwdriver until it was an awesome fit. Then I PB blastered up the jet. Then it was time for heat.

Success!

Using the torch and PB blaster I went after the damaged emulsion tube. I got it out. You can see how badly I buggered it up.

So now I've got another float and emulsion tube coming via ebay. I'm looking for recommendations on carb rebuild kits. As a minimum I think I want to replace the fuel transfer o-rings, the float seat o-ring, the float valves, bowl gaskets (which I'll probably make), and some of the other vent looking thing o-rings.
More to come...