FJ1200 rebuild

shuggyboy · January 31, 2011, 06:49:08 PM

Hi folks,

I introduced my self in the intro section, just thought i would post a couple of pics of how im getting on,,, got a lot done over the past few weeks,,, but still got a fair bit to do. I've had it running and it sounds brilliant....

I've been looking for a throttle cable for the "pull" side,, mine is working to test the engine,, but its frayed down to a wire!, there's one listed on the fjcatalogue but only does up to a 90?,,, mines is a 93,,, does anyone know if it will fit?, the throttle tube housing is separate from the switchgear and seems to be moulded cables designed to fit that type of housing,,, i think the earlier model might be different?

anyway, heres some piccys of how its sitting just now,,, I stripped it to the frame, painted the frame, engine, wheels, swingarm, forks, discs etc. started to polish the rims, polished the footpeg hangers etc,, i just used halfords aerosols, but went over it with a proper lacquer from the paint shop and airgun,, looks not too bad, and should be quite durable., got the chassis rolling again, exhausts mounted, subframes etc.,, the throttle cable is kinda holding me back from bolting more bits on..... plenty to do in the meantime,,, still got the plastics to paint, and a couple of repairs here and there,, im goni repaint the silver colour on the plastics and tank, and re-lacquer all the plastics and tank,, should look minted when done.... hopefully in about 2 or 3 weeks.... come on the good weather!!!!!!,,, im hoping the second gear will be ok i haven't drove the bike since i bought it in boxes!!, ive been reading a few articles saying how weak it is, hopefully the 93 engine should be ok,,

oldktmdude · January 31, 2011, 10:09:53 PM

According to Boatsnet.com, the cables were different '91- '93 compared to the earlier models. The earlier cables are sold individually, where as the '91-'93 cables come as a pair. The pre'91 cables may fit your bike, someone from the forum, with first-hand knowledge, maybe able to help out. Cost from Boatnet is around $73.00 for your model. Regards, Pete.

carsick · January 31, 2011, 10:13:08 PM

Damn, they sure weren't built with salt in mind. Nice resto job, you've been busy!
Doug

andyb · February 01, 2011, 06:48:44 AM

Quote from: shuggyboy on January 31, 2011, 06:49:08 PM
im hoping the second gear will be ok i haven't drove the bike since i bought it in boxes!!, ive been reading a few articles saying how weak it is, hopefully the 93 engine should be ok

Should be okay. Any bike that's beaten hard or ridden badly is likely to have second gear problems, but it was a bigger issue on the 1100's. The 91-93's had better shift forks, which help prevent the problem from starting in the first place.

First gear can also slip out, round the dogs, and bend the forks, but you hear about it less (normally just a problem for the racers).

craigo · February 01, 2011, 08:11:58 AM

And another FJ saved from the scrap bin. Well done, looks new!!!

Cheers,

CraigO
90FJ1200

Flying Scotsman · February 01, 2011, 08:23:11 AM

Looks great

Buster · February 01, 2011, 11:30:09 AM

Nice

racerman_27410 · February 01, 2011, 11:30:35 AM

Nicely done !

Kookaloo!

Mark Olson · February 01, 2011, 11:34:43 AM

Great job so far ,

I like the before and after pics so we can see how nasty it was before.

Travis398 · February 01, 2011, 02:54:46 PM

nice to see you are bringing her back to life

shuggyboy · February 01, 2011, 03:03:20 PM

cheers lads,

Ill post another couple of pics when i get a bit more done.

all the best

shuggyboy · February 02, 2011, 02:14:46 PM

Ive managed to get a bit of time to post it on my website..

http://www.shugtech.co.uk/new-projects-yamaha-fj1200/

more pictures been added there

RACER111V · February 02, 2011, 05:08:07 PM

I guessed by the corrosion that this was another UK bike. I thought bikes looked ruff over here in "new" england but you guys in the old country definitely have it worst. The rebuild is looking good.

shuggyboy · February 03, 2011, 04:13:12 AM

Hi folks,

This might sound like a daft question, but does anyone have a picture of where the horn is mounted?

It had already been removed when I bought it, and i want to make sure Im mounting it on the right place.

It looks like it might mount on behind where the splitter for the front brake bolts onto the bottom yoke, but im not sure. its a 93 model if that helps?

cheers!!!!

shuggyboy · February 05, 2011, 04:34:22 PM

I have laquered all the plastics, ill post a couple of pics tomorrow, but in the meantime, heres a wee video of the first start up video,,,,loads of smoke,,, but this is from the paint on the exhausts and the engine,,, hopefully its shouldnt take too long to burn away,,,,,

FJ1200 1993 first start up after rebuild

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FJ1200 rebuild