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Project FJ1200 ABS **COMPLETED**

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Fizzer Thou
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PostPosted: 21:17 - 26 Jul 2015    Post subject: Project FJ1200 ABS **COMPLETED** Reply with quote

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 Shocked

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

http://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.

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

http://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

http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20150621_201841_zpszanrjeiw.jpg~original
http://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 Rolling Eyes Wink Thumbs Up
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Last edited by Fizzer Thou on 19:26 - 12 Feb 2018; edited 2 times in total
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-Monty-
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PostPosted: 22:30 - 26 Jul 2015    Post subject: Reply with quote

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

Will follow with interest.
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chickenstrip
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PostPosted: 22:52 - 26 Jul 2015    Post subject: Reply with quote

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? Bounce!

Will be watching with interest to see how you go about cleaning up various bits and pieces.
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Kris
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PostPosted: 11:26 - 27 Jul 2015    Post subject: Reply with quote

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.

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

Keep at it! Cool
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flat spot
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PostPosted: 18:01 - 27 Jul 2015    Post subject: Reply with quote

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.

http://i289.photobucket.com/albums/ll201/flatspots_pics/P1010814_zpskeitazif.jpg
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J4mes
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PostPosted: 18:04 - 27 Jul 2015    Post subject: Reply with quote

For some reason I want to ride that a long, long way! Thumbs Up
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Fizzer Thou
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PostPosted: 22:43 - 06 Aug 2015    Post subject: Reply with quote

chickenstrip wrote:
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? Bounce!

Will be watching with interest to see how you go about cleaning up various bits and pieces.


There is about 22,000 miles showing on the clock and the old MoT certificates tend to support this as genuine mileage.From what I can make out the bike was sitting in a bike shop for some time before the previous owner bought it,with the intention of taking his overweight partner around the UK on it Confused
The PO did give me some bulwarks about this and that,like the rear shock damping was gone.But more of that as I go through the stages of renovating the bike.The PO had never kept the bike undercover,and neither had any of the previous owners either,as there was quite a considerable amount of dust and debris down inside the hollow spokes of the cast wheels Shocked

Mrs.Fizzer now has a new job,so the pressure is off to get the bike done as soon as possible.So I have been collecting new and old parts together for the rebuild,while trying to get other things done.
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Fizzer Thou
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PostPosted: 23:07 - 06 Aug 2015    Post subject: Reply with quote

Kris wrote:
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.

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

Keep at it! Cool


My swing arm is not quite as bad as that Kris,but bad enough that I do not want to risk myself and Mrs.Fizzer with a corroded standard swinger.
So I have sourced an ally item from an earlier model.A 3CV from what I can gather.Maybe Yamaha cheapened the bike by fitting a steel one instead of the more expensive ally one because of the ABS pump fitted to my 3XW Rolling Eyes
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Fizzer Thou
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PostPosted: 23:09 - 06 Aug 2015    Post subject: Reply with quote

flat spot wrote:
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.

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


I am liking the condition of this FJ flat spot Thumbs Up
If I can get my 3XW looking anything like as nice as the one in your pic I will be delighted Wink
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chickenstrip
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PostPosted: 23:23 - 06 Aug 2015    Post subject: Reply with quote

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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Fizzer Thou
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PostPosted: 23:41 - 06 Aug 2015    Post subject: Reply with quote

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

http://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 Thumbs Down
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

http://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

http://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 Wink

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 Thumbs Up

http://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

http://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 Evil or Very Mad

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 Thumbs Up

http://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 Thumbs Up

http://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

http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20150621_202218_zps87slwrom.jpg~original
http://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 Thumbs Down

http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20150621_202002_zpssj2qne0j.jpg~original
http://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 Thumbs Up
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Last edited by Fizzer Thou on 19:31 - 12 Feb 2018; edited 2 times in total
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yen_powell
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PostPosted: 06:57 - 07 Aug 2015    Post subject: Reply with quote

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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Fizzer Thou
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PostPosted: 18:58 - 10 Aug 2015    Post subject: Reply with quote

yen_powell wrote:
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.


Thank you for the offer of the genuine tool for adjusting the shims.I do not have any problems removing the cams on either of the 1000s so as to adust the shims that are 'under bucket',as against the ones on the FJ which are 'on top of bucket'.But if you have the correct tool,that would make things easier,so I would definitely be interested Wink Thumbs Up

PM sent Thumbs Up
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flat spot
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PostPosted: 22:04 - 16 Aug 2015    Post subject: Reply with quote

PM sent to fizzer Wink
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Fizzer Thou
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PostPosted: 20:32 - 02 Nov 2015    Post subject: Reply with quote

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

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

http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20150621_202504_zpsqyekjn1c.jpg~original
http://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

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

http://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

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

http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20150624_135707_zpsdscpewui.jpg~original
http://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 Rolling Eyes
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

http://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

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

http://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

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

http://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 Wink Thumbs Up
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Last edited by Fizzer Thou on 19:38 - 12 Feb 2018; edited 1 time in total
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Moxey
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PostPosted: 23:23 - 02 Nov 2015    Post subject: Reply with quote

Kris wrote:

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.


Off topic sorry, but any chance you remember who you bought the Pan off of? Sounds suspiciously familiar is all.....
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DJP
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PostPosted: 12:01 - 03 Nov 2015    Post subject: Reply with quote

Good work.

I love threads like this! Thumbs Up
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Mark65
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PostPosted: 12:22 - 03 Nov 2015    Post subject: Reply with quote

Looking forward to more Very Happy Thumbs Up
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flat spot
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PostPosted: 21:32 - 05 Nov 2015    Post subject: Reply with quote

Did you have to take the rear wheel out to remove the pump or did it come out at the side?
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Kris
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PostPosted: 20:29 - 07 Nov 2015    Post subject: Reply with quote

Moxey wrote:

Off topic sorry, but any chance you remember who you bought the Pan off of? Sounds suspiciously familiar is all.....


Not really, probably wouldn't recognise him now.

Did have a garage the other side of a small lane behind his house though if that helps.
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Fizzer Thou
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PostPosted: 20:21 - 09 Nov 2015    Post subject: Reply with quote

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


The ABS pump did come out via the side exit,but it was a bit of a squeeze.I removed the battery box fixing bolts which helped quite a bit Thumbs Up
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flat spot
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PostPosted: 10:20 - 14 Nov 2015    Post subject: Reply with quote

Fizzer Thou wrote:
flat spot wrote:
Did you have to take the rear wheel out to remove the pump or did it come out at the side?


The ABS pump did come out via the side exit,but it was a bit of a squeeze.I removed the battery box fixing bolts which helped quite a bit Thumbs Up


Righto thx.
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Bullet
Trackday Trickster



Joined: 06 Jan 2006
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PostPosted: 23:25 - 14 Nov 2015    Post subject: Reply with quote

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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past: ZXR750 J1, K1 & H1, GPX600R, Yamaha Radian. present: ZXR750 J2, SP-1, CB350
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Suntan Sid
World Chat Champion



Joined: 07 May 2009
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PostPosted: 00:01 - 18 Nov 2015    Post subject: Reply with quote

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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c_dug
World Chat Champion



Joined: 04 Sep 2007
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PostPosted: 09:40 - 18 Nov 2015    Post subject: Reply with quote

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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The last post was made 2 years, 246 days ago. Instead of replying here, would creating a new thread be more useful?
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