getting her back on the road

[Goetz]

I have a four day weekend coming up, going to hit the blue ridge parkway, this route here:...nm, wont let me post google map frame thingy, oh well
and this is how she sits now

DSC00238 by goetzjordan, on Flickr
the good: kookaloo, actually decent bridgestones, K&n pods (gonnahave to check the plugs and jets), and more kookaloo. chain and rear sprockes seem pretty fresh.
the bad: left fork dust cover is sopping wet w/ fork oil and i think the only reason the right one is dry is cause it already leaked out a long time ago. speedo cable snapped at the snail, odo stopped at 22k, the po had no comment. speedo needle assy. is laying in the bottom of gauge cluster housing, rear shock feels pretty dead. front brakes are MUSH. rear brake is TWITCHY. pod filters look pretty gunked up. tranny makes ominous clunking noises( in first & 2nd) but shifts smooth/ pipes are RUSTY. choke cable looks like the one that came with the bike, completely fubar'd.
i love this bike.
doing the f4i shock swap and fork seals as soon as they get in, do i need a fork seal driver? scotchbrite and grill paint for the pipes i guess. Im poor and already spent my last discretionary dime on a choke cable.

[markmartin]

i love this bike.
doing the f4i shock swap and fork seals as soon as they get in, do i need a fork seal driver?

Yes, but you can make one.  This related write up should help answer your question. Go to the bottom of the thread and open the attachement.

http://www.fjowners.com/index.php?topic=1911.0

[1tinindian]

Don't go crazy trying to fix it all in one shot.
It looks like you have a great starting point.
Just keep at it and before you know it, you'll have it in top shape.
You need to balance the fun of riding it with the fun of fixing what needs fixed, and modify what will give you what you're looking for.

I'm happy for you, because I remember what it felt like right after buying my FJ...feels pretty good, don't it?

Cheers,
Leon

[fj11.5]

+1 on the slow fixing, been working on and riding my effie for nearly 8 years, just keep finding other things to mod 

[Goetz]

yeah, i have some long term ideas for doing a carbon fiber overlay on all the plastics, but thats... long long term. I kinda go nuts at first, and i have to say, this is a sweeeeeeeeeeeeeeeet ride, even if it is slammed at the moment. Heh, best 800 i ever spent.

[SlowOldGuy]

The front brake caliper seals probably got contaminated with leaking fork oil.  I had that happen with the '93 I bought.  First thing I had to do was rebuild the calipers.

DavidR.

[Goetz]

yeah, the rotors were covered in a mixture of fork oil and brake dust, i imagine the pads are saturated, with oil  Im a little intimidated by the prospect of taking the front end totally apart, i've done a rear shock swap on an sv650n before, that was a breeze. but getting that needle back in the speedometer? bah. Has anyone had the gauge cluster apart here?

[fj11.5]

Most of us have probably had the gauges apart,  if i remember correctly its a squeeze getting the gauge cluster out on 1100s ,, but  pretty easy to work on once out just dont do the 4 cover screws on the gauge screen to tight,  or things make unhappy noises 

[Goetz]

Right on, thanks. I guess all i can do now is ride it till the parts get here

[Goetz]

 
went to bleed the brakes today, noticed brake fluid weeping from sight glass, BRUSHED it with my finger, and a chunk of plastic came out of it, followed by more brake fluid.
now my bike has a flipping moped master cylinder, which, after bleeding the brake lines, works WAAAAAY better than the stock one, will post pics later, im done.

[andyb]

Better to find that in the garage than at 70mph noticing your lap is wet and your stopping is notsogood...

Ick, nonetheless, though.   

[fj11.5]

common problem ? with standard masters, when I bought my 84 po had plugged up the site glass holes with metal mend or something, as the sight glasses had both fallen apart, , first upgrade was master cylinders for some reason 

[Goetz]

so there is a company that sells sight glass kits :http://www.google.com/url?sa=t&rct=j&q=&esrc=s&source=web&cd=1&cad=rja&ved=0CCkQFjAA&url=http%3A%2F%2Fnewrivercyclesalvage.com%2Fsight-glass.html&ei=iYtuUPOHOorQ9ATtq4D4CQ&usg=AFQjCNGH5avXfmLFXn2ewLevJJ7I997hBQ

but a dime fits in the hole pretty well and jb weld is cheap.... i know, i know, but my inner redneck is howling with delight at the prospect of putting Jb on the bike...

DSC00249 by goetzjordan, on Flickr

DSC00248 by goetzjordan, on Flickr

[Goetz]

well, i now have a moped master cylinder. it works, for now. Ordered a kit from new river cycle salvage, to replace the sight "glass" with real glass, will post updates if it works. 
had my first k&n pod cleaning experience. also, took the fairing off to find that 1) speedometer is totally hosed and 2) the light adjuster knob was hanging loose. also both air scoop things were missing mounting bolts (1 each) and the screws that held them to the air ducts that flow air to the head (ONE screw apiece) I think i have found the source of my low speed noise gremlins (I hope).
I just hope the engine is in better shape than the fairings and gauges. Anyone have a spare speedometer?
btw, dont try to paint stuff outside. I just gave up after having a bunch of dust and stuff get onto the air scoops AGAIN. the black is gonna look sweet tho. Any rattle can gurus out there?

[Klavdy]

Preparation is the key.
Thick, glugged on paint looks shit.
Take your time.
Put the rattle cans in a bucket of hot water for five minutes just before using.
Lots of really light coats are the only way to go.
Let the thin coats dry to a hard finish before sanding, 24 hours is best.
Sand between the coats.
Take your time.
Go to a big box store and get a big box, something that a washing machine , fridge etc came in.
Use that as your spray booth.
Take your time.