Upstate NY - FJ Refresh

[imagelessJAKE]

Hello all!

I recently became a FJ owner after finding an '86 FJ1200 tucked away and forgotten in the back of a mattress store - you can find my initial observations once getting in the garage here:

http://www.fjowners.com/index.php?topic=19795.msg202538#msg202538.

My goal: To get this bike safe and sport touring ready

The good news is I was able to get the bike running STRONGLY after some fresh fuel and oil, a new battery and a wash - so this will be more of a refresh then a full on restoration (My Honda hawk was a rough one so I am glad to say that )

Here is the current parts list I have ordered for to install on the bike (many thanks RPM):

• Brake lines
• Tires - Pirelli Sport Demons
• EK Chain
• Fork Seals/Wipers
• Fresh Battery
• Spin on oil filter adapter
• Magnetic Drain plug
• Handlebar Grips
• The Blessed Haynes Manual
• Clutch Line
• Throttle line
• Rear Blinkers

These of course were from the first casual inspection - more below:

[imagelessJAKE]

Deeper inspection:

Its got as fancy Super Trapp exhaust - I've heard these can be hit or miss - it seems to sound a little snotty but not so bad.

There is some electronic ignition attached - I am unfamiliar with these unfamiliar with these units - and the wiring seems to be somewhat of a cob job.

I need to do some more research on this and I need to see exactly why there is so many loose plugs - it looks like someone with a smooth brain got at it.  

You can see my own solder work here for the gas level sensor wires - this is temporary until I can get a new 3 pin connector - the old one had just about rusted out

[imagelessJAKE]

The plastics:

A little rough around the edges - but savable - after a serious cleaning the shine came through.
The belly pan though... lets say its seen better days - I will be looking into potential repairs on this(fiberglass and plastifix come to mind).

That is where the bike stands as of now with one afternoon with work.
I look forward to seeing other people's builds and seeking the sage advice from the brains on this forum!
have a great day and thanks for looking.

[Ted Schefelbein]

If nobody has told you yet, welcome aboard. You will discover, as did I, that having a support network like this makes the task of keeping an old Japanese motorcycle on the road much easier and cheaper then it otherwise would be. The tool rental is a hell of a resource, that I have already used.

There are updates to the wheels, tires, brakes and electrical systems that make the bikes head and shoulders above what they were. My bike was heavily altered, and I wasn't sure about buying a modified bike at first, but, it has been a pleasure. It was a three state road trip to get it, right at the lock down, an adventure my son and I will never forget. I had a bunch of work to do when it got here, but, the guys here made that much easier. Come spring, I have an oil change, clutch master cylinder rebuild, carb sync, 4 new plugs and compression test to do, hopefully followed by many trouble free miles this summer.

Enjoy. Always run an issue past these guys, first, they have likely seen it before.

Ted

My son with the new-to-us 1989 FJ, in the middle of Missouri, just before we loaded up and headed back to Minnesota.

[imagelessJAKE]

If nobody has told you yet, welcome aboard...

Well said and hugely agree - I am a younger guy so I unfortunately wasn't around when these bikes were in their prime. I come to all bike specific forums for advice of the members. Thankfully - unlike my other bikes this seems relatively tame and parts seem to be readily available - and like all vintage Japanese bike  owners we are enthusiastic!

I'm hoping to not have to take the carbs out and the clutch apart - but I am prepared to - but until an issue arises - best not to let the magic out!

[RevDeal]

Welcome! Love the rescue project. This group has a lot of information. If you have trouble finding the Dyna 2000 ignition manual let me know. I have one.
And not saying our bikes are the same but after my tear down I noticed a handful of unplugged connectors. All of them had a good reason and a modification. But it's hard to know unless it was your mod. Over time you'll figure it out as you tidy it up. The wiring diagrams were very helpful, but overall the harness is pretty tame on this bike.

Happy riding!
Jacob

[Motofun]

That type of extensive belly pan damage is often caused by a leaking clutch slave cylinder.  One of many things you can parts from RPM for.

[Millietant]

Welcome in Jake.......as others have said there's a wealth of knowledge and experience with these bikes here on the forum. I'm sure you'll get the bike in tip top condition and be out enjoying lots of trouble-free miles before too long.

The only thing I'd add to what everyone else has said is.......hot staple gun........brilliant for repairing plastics, with a bit of plastifix/plastex/fibreglass thrown in for good measure.

You should see what AviationFred managed to do with a hot stapler when fixing his broken FJ fairing...it was awesome  

Here's me and my 89 FJ in Jan's ("2Big" on here) garage last summer, with his project FJ peeking out from behind my bike. I've had mine from new, but did a refresh and a few extra upgrades 3 years ago.

[imagelessJAKE]

Welcome! Love the rescue project. This group has a lot of information. If you have trouble finding the Dyna 2000 ignition manual let me know. 

Thanks Jacob! I dont know much about electronic ignitions so any info would be much appreciated - right now it starts and runs well! so I'd rather not mess it with haha.

Is this unit to replace one that originally came on the bike? or is it a complete add-on?

[imagelessJAKE]

That type of extensive belly pan damage is often caused by a leaking clutch slave cylinder.  One of many things you can parts from RPM for.

Indeed - I've made a thin metallic layer I am going to use to support the bodypan and use some fiberglass to lay over to support it. I think I am going to plastifix some of the other issues and use a filler.

I'll take a look at the clutch slave cylinder and see if its leaking.. fingers crossed it isnt!

[imagelessJAKE]

Welcome in Jake.......as others have said there's a wealth of knowledge and experience with these bikes here on the forum. I'm sure you'll get the bike in tip top condition and be out enjoying lots of trouble-free miles before too long.

Wow! after some videos looking at them those are pretty neat tools - I wish i knew about it long before!

Love the two tone white on silver with red accents! Keep it rocking!

[imagelessJAKE]

Some other goodies from RPM on the way:

• 90* valve stems
• New Levers
• Petcock Rebuild Kit
• Choke Assembly Kit
• Fairing bolt kit
• Vintage Connections electric repair Kit
• Wheel Bearing and Seal kit front and rear

While the bike does run - I want it safe and steady and running at its best!

[imagelessJAKE]

Belly pan repair:

So with the damaged belly pan fairing - my primary issue is the fact it was split apart and had major cracking on the sides.

A thin metal piece was cut, bent and riveted in for support and strength - and fiberglass patching was used on the sides for additional support.

I apologize - its not my prettiest work but I think it its strong enough to hold the damn thing together long enough for me to find (or make?) a replacement?

If anyone knows good replacements for these pieces that dont cost an arm or leg let me know.

Edit: I apologize - for some reason photos coming through get weirdly compressed and blurry any way to fix this?

[Millietant]

New ones are available from the FJOC in the U.K. For a reasonable price (£89 I think) in gloss back or white fibreglass.

Not sure how much it would be with postage /shipping to you.

[FJmonkey]

Randy at RPM may still have one or two left. They are fiberglass after market (white). Drill and paint as required.