Project FJ1200 ABS **COMPLETED**

[Fizzer Thou]

This did not start out to be a project.The original intention had been to buy a bike that would take Mrs.Fizzer and I around Europe for a few weeks and then to either keep it for the following year or to sell it on as soon after returning or thereabouts.

But finding a suitable bike was the biggest problem.A friend has a Yamaha FJ1200 and it is more than capable of taking him and his wife abroad comfortably,fully laden with top box and panniers.

So,having tried that bike for size I started to hunt around for something in the £1000 area,but many machines for that expenditure had around 60-70,000 miles on the clock,were a long way from Kent and all needed some work doing to them,which was to be expected.Or I could pay through the nose for something from a dealer somewhere in the country with around half that many miles on the clock and in much better condition.

Eventually I located one in Eastbourne and came to an agreement of £900.On the outside it looked mainly cosmetic and a relatively easy job of changing a few bits and pieces,fit new tyres,locate some panniers that would go with the existing Givi top box and rack and then book the time away.

How wrong could I have been

https://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20150620_173059_zpsefhzgvou.jpg~original
https://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20150620_173123_zpstsdpeerv.jpg~original

The bike as I got it home looked reasonable on the outside.The engine sounded sweet but the fork seals had gone big time,puking fork oil all over the front calipers and in doing so had smothered the brake pads and discs with the same stuff.So I was right to have gone down with the trailer and picked it up.

https://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20150621_201700_zpsw37xrhuq.jpg~original

Once on the ramp I removed the next to useless belly fairing,which had to be removed anyway as I am going to fit some engine bars.But what I had not expected was the amount of corrosion hidden by the bodywork and plastics.The more I stripped off the more I could see that there was more work than I had originally expected.

So I started the engine and while waiting for the oil to heat up I had a gander underneath.At least the downpipes are stainless and will clean up with a bit of elbow grease.But pretty soon I realised that I was going to need it by the gallon if I was going to be happy to ride this bike around the Continent with any confidence at all.

https://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20150621_201748_zpscrwtdwsn.jpg~original
https://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20150621_201940_zpsobnu5zia.jpg~original
https://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20150621_202107_zpsyvastkrs.jpg~original
https://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20150621_202154_zpspcujgho2.jpg~original
https://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20150621_201930_zpstvq0ptqx.jpg~original


Luckily,some of the corrosion is only skin deep,like on the clutch cover

https://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20150621_201906_zpsakmzcr2o.jpg~original

But the back brake was going to take a bit more than I had at first anticipated

https://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20150621_201841_zpszanrjeiw.jpg~original
https://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20150621_202021_zpshrxbdkb7.jpg~original

So,as I work my way around the bike doing what I feel is required to get this bike roadworthy again,follow me as I take the necessary steps.It should make an interesting project.

I hope
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Just talk bikes.What else is there?

Always have a 'Plan B'

[-Monty-]

Looks like an interesting project, although a shame that it's an unexpected one

Will follow with interest.
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Present: [Kawasaki ZX7r][Suzuki DRZ 400s]
Past: [Honda PCX 125] [Yamaha RXS 100] [Honda CB 500] [Triumph Speed Four] [Honda ST1100 Pan European - Po-Po Edition]

[chickenstrip]

Kinda like those old FJs. A friend of mine had one many years ago - toured it to the Bol and many other places every year with no problems as I recall.

What mileage on this one? Did the owner tell you much about it, when he last used it, that kind of thing?

And what's the time limit before you're off on it? Is this a race against the clock?

Will be watching with interest to see how you go about cleaning up various bits and pieces.
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Chickenystripgeezer's Biking Life (Latest update 19/10/18) Belgium, France, Italy, Austria tour 2016 Picos de Europa, Pyrenees and French Alps tour 2017 Scotland Trip 1, now with BONUS FEATURE edit, 5/10/19, on page 2 Scotland Trip 2 Luxembourg, Black Forest, Switzerland, Vosges Trip 2017
THERE'S MILLIONS OF CHICKENSTRIPS OUT THERE!

[Kris]

Nice! Love those old FJs.

Years ago I was on the lookout for one for the same reasons as you but struggled to find anything decent anywhere other than dealers. I ended up buying a Pan Euro which, as it happens, also turned out to be a dog.

I wasn't as smart as you with your fancy pants trailer though so I had to ride back to Kent from Bishop Auckland with the exhausts hanging off. Only broke down once too.

https://www.bikepics.com/members/kris/94st1100/

Good luck with it. I see your fucked back brake and raise you a holey swingarm with extra rust.

https://www.bikepics.com/pics/2009/04/26/bikepics-1647955-full.jpg

Keep at it!
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NSR125RR - ZXR750H1 - ZX9R E1 - GSF600S - GSF600SK3 - VFR400-NC30 - SV1000N - ST1100-R - CBR900RR-R - GSF1200SK5 - GSF600SK1 - VFR1200FA - GSXR1000K2 - ZZR1400 D8F
www.prisonplanet.com

[flat spot]

I'll be following this because I recently got this that has been sat since '99. Needless to say the carbs are somewhat of a ball-ache.

https://i289.photobucket.com/albums/ll201/flatspots_pics/P1010814_zpskeitazif.jpg

[J4mes]

For some reason I want to ride that a long, long way!

[Fizzer Thou]

[Fizzer Thou]

[Fizzer Thou]

[chickenstrip]

Jeez, only 22k miles. How can people let a good bike go to rot like that? You'd at least think they'd punt it out before it got to that stage. Nice to see it will now get a new lease of life though.
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Chickenystripgeezer's Biking Life (Latest update 19/10/18) Belgium, France, Italy, Austria tour 2016 Picos de Europa, Pyrenees and French Alps tour 2017 Scotland Trip 1, now with BONUS FEATURE edit, 5/10/19, on page 2 Scotland Trip 2 Luxembourg, Black Forest, Switzerland, Vosges Trip 2017
THERE'S MILLIONS OF CHICKENSTRIPS OUT THERE!

[Fizzer Thou]

Once I had found out the right way to remove the seat I was confronted by this

https://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20150621_201827_zpssscyxna8.jpg~original

It is,from what I can make out,an alarm.But how it works/worked I have no idea as there is no key or instructions that came with the bike.Neither is there a toolkit
The black box inside of the tail unit is the ABS brain,something that has now been shoved to one side as it has been deemed U/S due to removal of the ABS pump.

But I also found a Scottoiler pump and reservoir

https://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20150621_202042_zpsxwpc5frd.jpg~original

Something which I am not sure whether to reuse or to sell on just at the moment.

The rot does seem to have set in into other places as well,like the oil filter housing,which is situated below the clutch slave cylinder

https://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20150621_202054_zpstleumark.jpg~original

The black paint on the filter housing might not that easily be repainted,so for the moment it is another item that I will sort during the initial stripdow of the important outer bits.
Up to this time I did not even have an owners manual or a Haynes,but I have no problems with stripping things down.It is the rebuilding that I am not thinking about just at the moment

The sidestand switch will be going as well as the old clutch hydraulic hose,as I am sure that a nice length of Aeroquip will look far better

https://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20150621_202127_zpsyfzv6uuj.jpg~original

But as I found the right way to remove the sidepanels,I was greeted by the rather large hole in the inlet manifold between the airbox and the carb inlet on #1

https://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20150621_202115_zps9kjzky0w.jpg~original

At 38 Euros each from CMNSL I might or might not order up all four manifolds

Luckily the oil cooler is not only relatively undamaged but also free of leaks around the hoses.I intend to clean this up and straighten as many fins as possible

https://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20150621_202142_zpscxkqcz5s.jpg~original


Not only that but the surface corrosion on the exhaust downpipes is relatively easy to polish up

https://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20150621_202154_zpspcujgho2.jpg~original

But the front discs and calipers,which are reputed to not be that good,were covered in fork oil from when the fork seals have blown

https://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20150621_202218_zps87slwrom.jpg~original
https://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20150621_202233_zpskbi4yyqy.jpg~original

Another good point is that not only are the downpipes made of stainless steel,but the silencers are made by Motad from the Neta range,so are known to last for a conserable time after standard would have rotted away ages ago

https://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20150621_202002_zpssj2qne0j.jpg~original
https://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20150621_202014_zpsz1rzvvrm.jpg~original

There is a bit of surface rust on the silencers,but nothing that cannot be cleaned off just before reinstallation
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Just talk bikes.What else is there?

Always have a 'Plan B'

[yen_powell]

You can change the shims on FJs without the special tool (which I have got somewhere if you want it). A small flat bladed screwdriver will pop them out in about 2 seconds.

Just turn the bucket till one of the notches is facing you, slide the blade of the screwdriver between the shim and the bottom of the bucket and as you push, twist. The screwdriver will now be between the shim and bucket. Another twist in the same direction as the first and the shim will pop out. You can push them back in with just bare hands. Of course this ease means they won't need doing anyway.

Don't use the small drain screw on the oil filter housing, the threads are like cheese, just take the whole thing off and let the oil out that way.
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Blackmail is a nasty word........but not as nasty as phlegm!
XT1200Z and a DR350 in bits

[Fizzer Thou]

[flat spot]

PM sent to fizzer

[Fizzer Thou]

Since my last post about the FJ I have been lucky enough to accrue a number of items from people like Yen Powell and other forumites from other sites.These have been put to one side while I have set about removing more parts from the bike,to be either cleaned up as I go along,or to be stove enammelled by a local firm.

But the paint between the engine fins is flaking off quite badly,which to me is a sign that the bike has been abused in its previous life

https://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20150628_171157_zps1qtvai9z.jpg~original
https://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20150628_171230_zpsvylatpnh.jpg~original


But underneath did not look as though it had been attended to for quite a considerable time as well

https://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20150621_202504_zpsqyekjn1c.jpg~original
https://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20150624_135620_zps7zypkelf.jpg~original

Having eventually removed the back wheel,with a difficult to remove wheel spindle,I was able to ascertain just how much I had taken on.
I had,from an early stage,decided that I was going to do away with the ABS system,as I had read that it was not that effective when new,so no matter what I did with trying to improve it,it would not be worth the effort.So,with some effort it was removed from its lair beneath the battery box

https://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20150624_135635_zpsytgqfrym.jpg~original
https://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20150624_135801_zpsg7zkhfkg.jpg~original

I was gobsmacked by how heavy the ABS pump is at nearly 7lbs

https://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20150624_190413_zpsu2gig5t0.jpg~original

More parts have been removed from the chassis and I have still not worked out how to remove the fairing at this stage

https://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20150624_135605_zps09k1kgac.jpg~original
https://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20150624_135552_zpsrkimskhb.jpg~original

But the view of the engine from what the petrol tank had hidden was not good either,with lots of corrosion with more flaking black paint

https://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20150624_135707_zpsdscpewui.jpg~original
https://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20150624_135651_zps2fbs8gux.jpg~original

After I had read through the Haynes manual that I had been sent by the PO I worked out how to remove the fairing.This entaled taking off the wing mirrors,the screen and the black inserts between the screen and the fairing.What a pallaver
But what I found inside of the fairing were fly lava and bits of string holding the speedo drive cable away from rubbing against other bike parts

https://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20150628_171514_zpsqakts6pu.jpg~original

With the fairing off I could see where I was going to have to spend some time with some silver Hammerite

https://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20150628_171332_zpsojlogzdi.jpg~original
https://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20150628_171047_zpsochocmam.jpg~original
https://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20150628_171057_zps3dmolxrn.jpg~original
https://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20150628_171106_zpsm3js3tqy.jpg~original
https://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20150707_173609_zpsjw1ybykn.jpg~original

But the tops of the carbs could not be ignored as they gave me eye ache every time I went by

https://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20150628_171318_zpsjbys8qdq.jpg~original

A quick wire brush of one carb top was enough to show that there was hope for the others as well,so I set about cleaning the others....or that was the idea.With four cross head screws per carb top,some came undone easily,whereas the others were about to give me a headache.In the end I was not bothered about reusing the old screws,having found sufficient numbers of stainless allen screws of the right size

https://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20150701_164257_zpsfjlvilow.jpg~original

https://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20150808_215233_zpskahb9w10.jpg~original

There is much more to be done yet and the box of bits to be stove enammelled is beginning to burst at the seams.More to be posted soon
____________________
Just talk bikes.What else is there?

Always have a 'Plan B'

[Moxey]

[DJP]

Good work.

I love threads like this!
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Suzuki Bandit 1250
https://deejayp999.atwebpages.com/index.html
That's http not https

[Mark65]

Looking forward to more
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07 Yamaha YBR125, 07 Honda CG125 , 15 CBR300R (Chocolate Crank, Deaded), 16 CB500FA, 19 Honda Forza 300, 70 Suzuki SV650

[flat spot]

Did you have to take the rear wheel out to remove the pump or did it come out at the side?

[Kris]

[Fizzer Thou]

[flat spot]

[Bullet]

looking good, but going from the state of just the carb tops alone id be strongly tempted to take the whole carb rack off, strip and ultrasonically clean them! i couldn't ride a bike round europe knowing they were in that state, id be permanently paranoid they would crap out on me!
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nonstop unicorns vomiting sunshine pills into a rainbow toilet
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past: ZXR750 J1, K1 & H1, GPX600R, Yamaha Radian. present: ZXR750 J2, SP-1, CB350

[Suntan Sid]

Fizzer, in case you didn't know, there's an article in this months Practical Sportsbikes on fettling and restoring FJ's!
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"Everybody needs money, that's why they call it money!"

[c_dug]

I might have a rear calliper around somewhere from a Diversion 900 (looks to be identical from memory) that you're welcome to for the price of postage if you need it?
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I am a bellend, I am a man of constant sorrow, I am a gummy bear, I am a rock.