85 1100 gets 4AY 1200 motor with wild cams and Mikuni 38mm flat slides

[Troyskie]

Well FJOwners I've been lurking, just not posting  .

The project bike concerned is my brothers 85 1100 purchased back in 97.

Here's what we know if it's provenance.
Originally purchased in 85 out of Townsville QLD Oz in 85. Was rented out of Cairns till written off by 'Japanese tourist' (well at least the FJ beat the crocs ). Rebuilt and found its way to Perth Western Australia, where it was bought by my bro Mark.

By some quirk of fate I was the first to ride it. In reality we flattened the battery trying to start it and I happened to be the lucky chap taking a break from pushing and was in the saddle when it finally fired up.
A 100m round trip back to Mark was my first ever FJ riding experience.

From memory it only had around 15k on the ODO.

Over 600,000ks and nearly 38 years later this project begins.
But it is not nearly the first work on the bike.

Here's a summary:

• It was Marks only means of transport for nearly 10 years
• It took Mark around Australia over 1.5 times in actual laps
• Mark rebuilt much of it
• In 94 it was given a JMC IOM racing swingarm. Mikuni Flat slides. Wiseco 3rd oversize HP kit. New bottom case as the write off had cause a crank leak. Wiring upgrade and extra stator windings on the alternator. Jetted to run AVGAS. 88 Front end. 88 motor with wild cams(but was subsequently removed and original reinstalled and cams installed in 1100). Ohlins fork springs and rear shock upgrade. New fairing (after mishap going over a railway crossing at, um, a 'safe' speed ?)
• Ridden hard for the next 10 years putting on about 300,000ks
• Parked up for most of the next 5 years
• Left with me for two years
• Given a top to bottom refresh, pistons left alone after compression test and head removal showing mint engine even after so much use. Original crank still in new specs
• Sent back to my bro ready to go
• Used heaps till he scored a Kwaka 1400GTR
• Went to sleep
• Woken up for a revival trip across the Nullarbor for one last ye ha
• Now we start the mini project

Here's some pics of Marks fun with the bike from the 80s & 90s. The clear photo of effie in the garage is showing him sleeping for 7 or 8 years

[Troyskie]

Allrighty that's the intro.

What am I doing?

Well, this is a sentimental project with a bike I've ridden for almost 38 years.
It will be turned into a track bike that is road registered, and somewhat period correct (thinking about USD forks here ).

So, here we go.
A mate of mine, Gav, another Oz member, found himself flying through the air when he last thought he was riding his 4AY 1200.
After the ground rudely interrupted his flight he found that consciousness, a spleen, some other skeletal continuity, riding buddies and a motorcycle were suddenly absent.

Gav and his bike had unintentionally joined the "it was at that moment" brigade. A short flight down a 10m rocky embankment over the armco to amazingly land and not splat on the fucking pointed rocks all around. Really  really lucky.

Gav still rides and donated his FJ to the local community, of which I'm one & now I can add his history to Marks.

Gavs' bike has a genuine 120HP at the back wheel. I was there at the dyno run and can probably get a graph. I might have posted it here as well......(Pat, any idea?)

I can't remember what Marks engine had, but compression was good, but a tad low for Wiseco HP.
However, this bike has been both Marks and my main transport for almost 38 years on and off.
Time for a change, and Gav's mishap is our opportunity.

[Troyskie]

Here we go, strip down. Day 1.

[Troyskie]

Day 2. We're taking our time ok?

Every second bolt, nut or screw strips.
It's like losing the will to live.
I LOVE this project!!!!! As I realise I remember this what I think throughout every every Fj project.

The cam swap was pretty straight forward.
It was much helped by Pete's competence and experience.

Some years ago I was fortunately able to purchase two sets of complete FJ screw, nut, bolt and washer set from wreckers out of Japan.
They literally arrived in the post in one bag for each bike but all mixed together.
My kids still remember fathers day one year sitting in the shed with dad sorting the mess into like piles.
I really love being able to go to my FJ stores and being able to find an exact nut, bolt, screw, even washer or weird damper that came in those bags.
Those bags of bits truly made this mini project so much easier. Please Japan, for what ever reason you stopped, please wreck bikes with the components together again.

Anywhoo, now to really getting frustrated.

Fucking cams!!!!!!!!!

Ok, it's me, not the cams, or the tools (Troy you're such a tool!!!!!!!), it is me.

Pete and I spent hours doing the shims. Knock off, sleep on the project and hook in the next morning. The shim measurements are different and not by possible error, waaaaaaaaaaaaaay out.
What's wrong?
Is it our fault? (YES )
What did we do wrong? I'm not sure but I think it's called beer.

Those fucking cams! As the cams were welded they are substantially wider than standard.
As they're wider they push the cam bucket tool away from the edge of the cam bucket.

We had to modify the shim tool that holds down bucket to suit modified cams.
The modification was simple. When the tool is used on standard cams a light witness mark is left on  the casting surface.
Essentially the cam lobe was wider and needed more clearance, so we used my Dremel thingy to make it work by careful grinding away and smoothing around the witness mark on the shim tool creating more clearance between the cam lobes and the cam shim tool.
This worked and we were able to finish putting the motor together.

I'll not bother with the valve cover or other simple things.

Getting the motor in without scratch was impossible for us.

It went in and we did the job, but it was not as neat at we thought or you would like.

Because I chose to not remove the forks or subframe I made the job much harder and trickier.

Pete Jono and myself wiggled, lifted and worried effie onto the frame.

We've learnt a few lessons along the way that you are probably laughing about right now

[Troyskie]

Here's some pics

[fj1289]

I love these type of projects - keeping a loved bike on the road and making it even better!




But ... the Effie naked 28 picture NEEDS an epic Klavdy post and picture in response!

[Waiex191]

That's really awesome Troyskie!

[T Legg]

I'm ignorant Troy. What's a 4AY 1200 engine out of ?

[Troyskie]

The 4AY is a FJ1200B that first entered production in 1991 and is basically one of the last variants to be produced. There were still a number of 4 series variants developed between 91 & 95, however the very last variant produced in 1995 was the 4AY, with about 900 made. These were sent to 'Oceania', which I assume means mostly Oz and NZ, however I did see a later model FJ in Fiji once.

[T Legg]

How did you handle the difference in the bottom rear engine mounts?
 I just finished putting an engine from an xjr1300 in my black 84 FJ1100. I couldn't find a machine shop that would drill the holes to fit the larger mounting bushings so I had to drill the holes out myself.

[Billy Bananahead]

How did you handle the difference in the bottom rear engine mounts?
 I just finished putting an engine from an xjr1300 in my black 84 FJ1100. I couldn't find a machine shop that would drill the holes to fit the larger mounting bushings so I had to drill the holes out myself.

I've put an XJR1200 engine in my 3CV and just left that mounting point you're on about empty.
It doesn't seem to make any difference as to whether the torque from the engine pulls it to the side, it is held solid.

[Troyskie]

We didn't do anything on the rear at all Travis, it slipped in like a banana on stage. But we did um-and-ah as another Oz member did the same thing and had the same issue as you.
Perhaps the 4AY motor being an early bird, this one is VIN # ...204, makes some difference?

I thought my bro had replaced the bottom half of the case with a later model as the lower frame rails are 1200, but when I asked he said it was the top, but that doesn't make sense as the engine # is the same and not 're-stamped'  .

[Troyskie]

Day 3.

I missed the final part of day 2 which was to run the engine with the new cams before cracking on with the rest of the assembly. Here's a link to the vid. https://youtu.be/D1URj6RKUB0 I've made it private, so let me know if you can't access it I'm still pretty unfamiliar with publishing on YT.

Now that we had the motivation of a runner in the frame it was time for dinner, drinkies, fire and tall stories  .
Now day 3 actually starts.

I had an excellent time on the Gerni removing 30 years and over 300,000ks of chain lube, road grime, bits and pieces of who knows what from the rear wheel, chain guard, shock, dog-bones and that cool swingarm.

Whilst Pete and Jono dealt with the wiring shit-fuckery and relay shenanigans I popped the swingarm, shock, and other bits in with Pete & Jono helping on the footpeg plates.

The clutch slave had a little spasm and decided to lock-up. It was a very new OEM one, but luckily my FJ stores came to the rescue again and we had a slave rebuild kit ready to go. None of us had ever refurbed a slave successfully before, but with the support of copious beer we somehow got it right, re-assembled, installed, bled and working (kinda but more about that later).

I've never had to deal with the type of swingarm rear wheel adjuster like this JMC one before. The axel was different, and I stupidly pulled it apart without taking photos or notes so re-assembly was put off in favour of continuing with all the other things we needed to to get the bike road ready and left the rear wheel for later.

As you can imagine there was lots of fiddly bits and awkward moments but with a couple of mates who know their way around and FJ it was all pretty fun.

Pics below

[T Legg]

We didn't do anything on the rear at all Travis, it slipped in like a banana on stage. But we did um-and-ah as another Oz member did the same thing and had the same issue as you.
Perhaps the 4AY motor being an early bird, this one is VIN # ...204, makes some difference?

I thought my bro had replaced the bottom half of the case with a later model as the lower frame rails are 1200, but when I asked he said it was the top, but that doesn't make sense as the engine # is the same and not 're-stamped' 

 The hole in the bottom rear engine mounts of the xjr engine and I think the 89 and later fj rubber mounted engines are about 13 mm and the holes in the fj1100 and early fj1200 are 28 mm. I drilled mine out to 28 mm. Maybe your engine was already drilled out

[T Legg]

Before and after drilling.