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Project FJ1200 ABS **COMPLETED**

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Fizzer Thou
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Joined: 06 Aug 2011
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PostPosted: 19:49 - 25 Nov 2015    Post subject: Reply with quote

Bullet wrote:
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!


I will be having the carbs apart to check them as a matter of course.The bike ran okay when I was looking it over with the intention of buying,but was unable to ride it because of the state of the front fork oil leak and the drenched front discs Thumbs Up

But thank you for the suggestion Wink
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Fizzer Thou
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PostPosted: 19:52 - 25 Nov 2015    Post subject: Reply with quote

Suntan Sid wrote:
Fizzer, in case you didn't know, there's an article in this months Practical Sportsbikes on fettling and restoring FJ's!


I am off to Malta for a few days tomorrow and I have a copy of that magazine to read on the flight out Thumbs Up
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Fizzer Thou
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PostPosted: 19:53 - 25 Nov 2015    Post subject: Reply with quote

c_dug wrote:
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?


That is very generous of you c_dug Thumbs Up

PM sent Wink
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Fizzer Thou
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PostPosted: 23:45 - 21 Jan 2016    Post subject: Reply with quote

With more parts like the fairing removed it was easier to access areas around the cylinder head

http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20150628_171342_zpsdrskaum8.jpg~original

And what a state it is.Thinking about it,the ducting from the side of the fairing directs fresh air around the top of the engine so as to aid cooling.Which means that the oil cooler becomes even more important so as to not let the engine overheat.Luckily the oil cooler is in reasonably good condition

http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20150628_171418_zpsxssl2cgs.jpg~original


But the frame itself is quite corroded in places where it has been exposed to the elements

http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20150628_171403_zpsq8m50uiq.jpg~original
http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20150628_171428_zpsdqewwk9u.jpg~original

This will entail removal,grit blasting and repainting before being refitted,something that I can do myself and not be too worried about the finish,as I can always go back to this at a later date after our Euro trip

But the area around the headstock,which has been protected by the fairing is in much better condition

http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20150628_171457_zpsyd3tu3qb.jpg~original

Next I turned my attention to the back end of the bike.With the swing arm out and the shock removed,I decided that it may well be worth stripping it down to see if what the previous owner was correct about whether the shock no longer had any damping left and if it was beyond hope

http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20150701_164223_zpskvqwd4rk.jpg~original

Using my new spring compressors,the first thing was to remove the spring so that the the large 'C' clip could be removed

http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20150707_173504_zpskgul8v2m.jpg~original
http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20150707_184748_zpsfjko03kf.jpg~original
http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20150707_184808_zpsj7ijyfkd.jpg~original
http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20150707_231219_zpsrlezw7m8.jpg~original
http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20150707_231329_zpsovwjfjlp.jpg~original

After a bit of a cleanup,the shock was easily compressed and released and the various settings of the rebound damping adjuster were tested through the nine steps that are suggested in the owners manual.What the PO of the bike had failed to ascertain was that the damping adjuster was miles out of its suggested minimum,which would have suggested that the shock had lost all of its damping ability.With the damping set to maximum,there was plenty of resistance.That will save me some 250 buying an aftermarket shock in that case.....

With the swing arm out and a quick degrease,the amount of corrosion was immediately evident

http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20150707_173804_zpsk64nllce.jpg~original
http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20150707_173813_zpsxl6wsc9l.jpg~original
http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20150707_173823_zps6pe00r09.jpg~original

One of many FJ forums suggested that an ally swing arm from an earlier model would be a direct swap,so I managed to find one for 60 delivered.This was preferable to having the corroded steel swing arm painted after checking to see if it was structurally sound,which would have worked out more expensive.
The ally swing arm does look better alongside the steel one Very Happy

http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20150715_161158_zpsgcvgnbfr.jpg~original
http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20150715_161209_zpsulan7t1a.jpg~original
http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20150715_161235_zps3kld4n86.jpg~original
http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20150715_161247_zpshi5lpp9n.jpg~original

With the swing arm out of the way the rest of the suspension and linkage could be looked at more carefully.Luckily the spindle did come out a lot easier than the rear wheel spindle did

http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20150701_164150_zpslvtgryq9.jpg~original

With a bit of a scrub it cleaned up reasonably well....

http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20150701_183718_zps5ej14ghp.jpg~original

http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20150701_183730_zpsox8egyxu.jpg~original

But in order to remove the suspension nuckle I would have to remove more of the exhaust system,something that I would prefer not to have to do if I can avoid it.

So.Within a very short time I have amassed a large number of parts that will have to be cleaned and inspected and I will have to decide which parts will need to be replaced or just cleaned and repainted/polished

http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20150701_164319_zpszmkbdrg8.jpg~original

But I also have some other spare parts from another bike that could be adapted should I so please.I have some handlebars from a scrapped CBR1000FH which are 41mm where it matters on the fork legs,but they are a lot lower than the standard bars,the left one of which is bent

http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20150707_173609_zpsjw1ybykn.jpg~original

This could be an option if I am unable to source a replacement.But with the main idea of having a far more upright riding position in the back of my mind,mainly so that Mrs.Fizzer has a more comfortable time than when we ride together on the sport bikes,I will more than likely do my best to source a good condition left handlebar.But the CBR items are an option Wink

So this is the state of the bike as it is at the moment.Not much has been done to the bike recently,mainly as it is too cold outside.But also because,if the weather has been reasonable I have been riding out on the dirt bike.But now that there is a deadline of booking the last week in May and the first two weeks in June for our time away,there is now an incentive to get on with the project

http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20150709_180535_zps4r2sjco5.jpg~original
http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20150709_180551_zpsnw9xzgm2.jpg~original
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Last edited by Fizzer Thou on 19:46 - 12 Feb 2018; edited 1 time in total
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temeluchus
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PostPosted: 13:38 - 02 Feb 2016    Post subject: Reply with quote

I owned an identical 3XW with roughly 120k or so on the clocks.

The rot between the fins was present although the head didnt seem as bad.

The swingarm was quite corroded so i slung a 3CV swinger on it. Close inspection revealed the steel item was a bit thin in places. The linkage had all new bearings and collars as they were all worn, the large bearing was positively rotten.

The other issues were a break somewhere in the loom that rendered the starter button inoperable and a duff starter.

I have a couple of starter solenoids if you want them.
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Fizzer Thou
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PostPosted: 00:26 - 09 Feb 2016    Post subject: Reply with quote

temeluchus wrote:
I owned an identical 3XW with roughly 120k or so on the clocks.

The rot between the fins was present although the head didnt seem as bad.

The swingarm was quite corroded so i slung a 3CV swinger on it. Close inspection revealed the steel item was a bit thin in places. The linkage had all new bearings and collars as they were all worn, the large bearing was positively rotten.

The other issues were a break somewhere in the loom that rendered the starter button inoperable and a duff starter.

I have a couple of starter solenoids if you want them.


The solenoids would be helpful as I have heard that they can be a problem.

PM sent Thumbs Up
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Fizzer Thou
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PostPosted: 23:17 - 24 Mar 2016    Post subject: Reply with quote

Ah yes.The brakes and the wheels.What a state they were in.But not a surprise really when the rest of the bike was taken into consideration Rolling Eyes

Because,as I stated earlier,the fork seals had gushed out more oil than the Torrey Canyon,the front discs and calipers would need a good seeing to.Once I had removed the discs from the wheels I could see that there was not much wear at all and that hopefully,all that they would need would be a good scrub Neutral

http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20150709_180639_zpsbbgqkqdd.jpg~original
http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20150709_180616_zpscfer0qrb.jpg~original

Once I had removed the rear disc,I remembered that I had some V-Max wheels,together with discs,given to me.So I compared all that I had and luckily,the OEM 3XW FJ rear disc is exactly the same as one of the spare front V-Max discs Smile

http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20150715_172506_zpszxpesdjy.jpg~original

So then I compared all of the spare V-Max discs and found that even the pattern rear disc from the V-Max had the same dimensions as the OEM FJ disc.So I will have a choice of which disc to use,either the solid pattern item or a ventilated standard one Thumbs Up

http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20150715_172439_zpsfqvwa7ea.jpg~original
http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20150715_172617_zpsz3y6bz5y.jpg~original
http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20150715_172630_zps6ix0n2kh.jpg~original
http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20150715_172453_zpsnewcytae.jpg~original

But I had a feeling that it was going to be the calipers that I was going to have the biggest job to sort out Neutral

http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20150728_105746_zps6jit4rpr.jpg~original
http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20150728_105902_zpsx3p81wsq.jpg~original

Actually splitting the caliper halves was not a problem.Getting the pistons out,without using any special tools,was relatively easy,as I have a rig on the workbench,which is basically a bent handlebar with a front master cylinder mounted to it,with a length of old hydraulic rubber hose fitted.This makes it so much easier than trying to do this job on the bike or on the floor.

So,the caliper pistons came out after a bit of a faff,mainly due to the corrosion behind the seals Sad

http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20150729_105512_zps6rh4oorw.jpg~original
http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20150729_105602_zpsime8qjzu.jpg~original
http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20150729_105552_zpsus44loof.jpg~original
http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20150729_105627_zpsgzbramcg.jpg~original
http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20150729_105534_zps8dezms7s.jpg~original
http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20150729_105543_zpswlhso0go.jpg~original

The piston seals are in reasonably good condition Wink

http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20150729_105641_zpskcim7ypy.jpg~original
http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20150729_105648_zpsbvnrj1sp.jpg~original

But the caliper half seals are beyond help and so will be replaced Shocked

http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20150729_105704_zpsymga3d9e.jpg~original

After quite a bit of scrubbing,the rear caliper halves polished up okay Thumbs Up

http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20150729_234350_zps0qibpinz.jpg~original
http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20150729_234255_zpsswgvzfpa.jpg~original
http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20150729_234321_zpsqo3enp10.jpg~original

While I had the rig set up on the bench for doing the brake calipers,it seemed a good idea to do the clutch slave cylinder service at the same time.Once I had removed the piston there was not as much corrosion as I thought there would have been.But worth the effort nonetheless.The piston itself is quite worn and,as I made a new one for the Exup1000 out of dural,the original FZR-R item may well be used to replace the FJ one when I come to refit the slave to the bike

http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20150811_150925_zps8ittljyp.jpg~original
http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20150811_151000_zpsk9au0wfg.jpg~original
http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20150811_150937_zpsojukhwhp.jpg~original
http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20150811_150950_zpsbeo2laga.jpg~original

As for the front calipers,after a good wash with hot soapy water to remove the worst of the grime,I split the caliper halves to see what I half suspected Shocked

http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20150811_172809-1_zpss8g2wvdo.jpg~original
http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20150816_164839_zpsykx0v4wp.jpg~original
http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20150816_164849_zpsihvhzrrt.jpg~original
http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20150816_164922_zpstrqudi4q.jpg~original
http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20150816_164910_zpsxax9wm0p.jpg~original
http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20150816_164900_zpsvwm1h7rs.jpg~original

On this particular caliper half,the edges of the pistons were chewed up,most probably from someone trying to extricate them from the caliper half using a pair of pliers.But with a bit of effort they were removed okay without having to be heavy handed.Not a pretty sight inside Neutral

http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20150811_172743_zpshihe1mkm.jpg~original
http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20150811_172713_zpsw7oxwgbv.jpg~original
http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20150811_172701_zpsrnxid0op.jpg~original
http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20150816_175345_zps3g6szlth.jpg~original

Talking of corrosion,the wheels had not been looked after either.The liberal application of grease onto this sealed for life bearing shows the experience of the person doing the work

http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20150709_180708_zpsazbdrrbd.jpg~original
http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20150709_180730_zpshwicixop.jpg~original

And then there was the total lack of any grease whatsoever on the top and bottom bearings of the fork yokes Shocked

http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20150709_181446_zps33ksgg7n.jpg~original

The petrol tank was a similar item that had not ever been looked at with any care Crying or Very sad

http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20150708_134035_zps4hpu2u0e.jpg~original
http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20150709_181345_zpsybmwla1h.jpg~original

Thankfully the tank was not leaking in any areas where the rust had started to take hold,so a good brush down with a wire attachment in the electric drill meant that two coats of white Hammerite made the world of difference. There is a thermal pad that sticks onto the underside of the tank,but the adhesive has proved to be a sod to remove,so that can be done at a later date Thumbs Up

http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20150819_155721_zpsza9qxdtc.jpg~original

When I bought the bike,part of the deal was for a pair of brand new ABE fork stanchions Thumbs Up

http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20150714_145657_zpsvo9h2vp5.jpg~original

The old ones were pitted quite badly,considering its mileage Shocked

http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20150714_145600_zpsjtnhjlcc.jpg~original

For some reason the preload adjuster fork caps were a bit mullered,as though they had been attacked with a mallet.After a bit of attention,the one on the right polished up okay.The other polished up the same way not long after

http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20150714_145445_zpsu3bhoz8f.jpg~original

The forks will be rebuilt with new oil seals and the prescribed amount of fresh 12.5w fork oil (a bottle of 10w and a bottle of 15w mixed).So that I can do up the big bolts that go in through the bottom slider into the damper rod,I sourced an old 3/8" drive Imperial socket and a nut which fits into the top of the damper rod,so that when it is time to assemble the forks with new slider bushes etc,this tool will make things easier Thumbs Up

http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20150714_145832_zpsenrqfbdd.jpg~original

More updates to come over the weekend,due to the shyte weather that has been forecasted Rain Rain Rain
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Last edited by Fizzer Thou on 20:01 - 12 Feb 2018; edited 1 time in total
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Vitesse
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Joined: 21 Dec 2011
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PostPosted: 00:37 - 26 Mar 2016    Post subject: Reply with quote

Having had 2 x FJs I've got to say that this tallies with what I found; that the 3XW/ ABS model was put together a whole lot worse than the earlier 3CV.

My 3CV had done over 105k miles when I sold it and still looked good. The ABS one I bought later had 30k on it and looked dire.

The quality of components was lower. Really just little things but for example on the 3CV you had gold anodised brake calipers and rotor centres (grey paint on 3XW), alloy swing arm (painted steel on 3XW), chromed cambox screws (plain steel on 3XW), self cancelling indicators, etc.

However they are still excellent bikes and yours looks to heading to being a nice one. Re brakes; I'm sure you know it but R1/Thunderace blue spot callipers are a straight replacement and in my case were cheaper than an original seal kit.
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af1
Borekit Bruiser



Joined: 09 Mar 2016
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PostPosted: 13:45 - 26 Mar 2016    Post subject: Reply with quote

Great work , loving this rebuild Very Happy
keep this coming please
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Fizzer Thou
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PostPosted: 13:46 - 26 Mar 2016    Post subject: Reply with quote

Thank you for your comments Vitesse.

Not only the FJ models but also many other Yamahas like the Exup-R and Ru models also had improved braking by using blue,silver or gold spot one piece calipers from other models.I have the original FZR-R four pot cailpers that I am going to look to install on the FJ as the pads are exactly the same and will bolt straight on.The other reason for using the FZR-R caliper is because I know that they have brand new seals installed.The only reason I did not use them on my Exup was because I bought some 6 pot calipers from a YZF750R which bolted straight on and which are a big improvement over the OEM 4 pot items Wink Thumbs Up
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Vitesse
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Joined: 21 Dec 2011
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PostPosted: 18:29 - 26 Mar 2016    Post subject: Reply with quote

Reading my post again it looks like I'm knocking your efforts which wasn't my intent. You're far more diligent than me as the little irritations were such that I just sold the bike. In fact I bought my old 3CV back again afterwards!

You should end up with an excellent bike at the end of it all. It's an FJ so the heart is sound. Sadly, all your work will be invisible to most people and you'll never get back what it will cost but that's never the popint.
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Fizzer Thou
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PostPosted: 20:58 - 04 Apr 2016    Post subject: Reply with quote

There are quite a few people on the FJOC forum that have chnged the back wheel from the narrow width 16" rim to a different one,mainly because of the limited choice of decent tyres.Those that are available are far more expensive for what they are and it is because of this limited availability that I have decided to go for a wider 17" wheel,one of which I just happen to have as a spare for the Exup1000.This will comfortably take either a 180/55 or a 170/60 on its 5.5" rim,so the tyres will be easier to find while abroad,should the occasion arise.

http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160331_162730_zpsthjfwvv1.jpg~original
http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160331_162756_zpsskg3ykfx.jpg~original
http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160331_162828_zpsfwhm9qox.jpg~original
http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160331_164033_zpsllsnjixe.jpg~original

I have three Exup rear wheels in total,so it was easy to place the replacement 3CV ally swing arm into the Workmate so as to size up the options.With a bit of machining here and there I can make the sprocket carrier fit to the Exup wheel and the FJ brake disc is a direct fit,so not much should need adjusting on the rear caliper bracket

http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20150802_135507_zps0y1zbski.jpg~original
http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20150802_135457_zpsyncnz9kk.jpg~original
http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20150802_135441_zpsiiatvygg.jpg~original

The spare back wheel for the Exup has a tyre and disc fitted,so it was relatively straight forward to size up what needs doing.My vernier caliper will come in very useful for this modification Thumbs Up

http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20150802_135120_zpsr4kgqvnp.jpg~original
http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20150802_135106_zpsejuf5tch.jpg~original

Some parts of the bodywork have cracked in places,either from mishandling or from the damage suffered by a sideswipe by a car.This was the reason for the bike being sold as a Category D write-off.The main reason for writing the bike off was because the top fairing is no longer available,and if they were able to source one,the cost would have been more than the value of the bike.But certain parts have been repaired using plastic glue and a soldering iron

http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20150914_171741_zpsctveumfd.jpg~original
http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20150914_171643_zpso9tv0grd.jpg~original

With the wheels put to one side for the moment,I decided to have a look at a few other areas on the bike.I have read about a 4 degree advance modification that can be done to the ignition sensor backplate,so I took the cover off,only to find that one of the cover screws was stuck in place with glue of some sort.The cover has some surface damage which can be polished out.But the stud will take a bit more time

http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160219_170121_zpschdbbdea.jpg~original
http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160219_144025_zps637i13xk.jpg~original

With the oil cooler removed so that I could clean up between the fins on the barrel and cylinder head,I thought that it would be relatively easy to unbolt the corroded oil feed pipes from said cooler so as to clean them up and to repaint them.How wrong was I Evil or Very Mad

http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160219_170053_zpswpr8vsfr.jpg~original
http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160219_170103_zpszllwgbyx.jpg~original

But it was when I pulled the wiring loom away from where it was zip tied to the inside of the frame and alongside the engine that I got the biggest surprise Shocked Neutral Confused

http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160219_143854_zpsahmj8lav.jpg~original
http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160219_143944_zps69fyu0p1.jpg~original

Some people on the FJOC forum said to replace the frame,but a friend who is a professional welder with an industrial 3 phase TIG welder said that it would be an easy job to weld a plate over the corroded area.Luckily the other area of corrosion was only surface rust and had not gone right through.I can only assume that where the bike had been kept outside most of its life,it was not difficult for corrosion to get to places.Annoyingly.And I say that because this would mean having to remove the engine.Which is no big deal really,but it was something else that I did not want to have to do.
____________________
Just talk bikes.What else is there?

Always have a 'Plan B'


Last edited by Fizzer Thou on 20:09 - 12 Feb 2018; edited 1 time in total
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Fizzer Thou
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Joined: 06 Aug 2011
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PostPosted: 22:39 - 01 Aug 2016    Post subject: Reply with quote

Well,now that I have rebuilt the bike and been away on holiday for three weeks around Europe,I can attempt to update this page.The bike ran fine for the entire journey of around 3,000 miles except for a slight hiccup in a wet street in Brussels.But I would prefer to put that place as far behind me as possible Rolling Eyes

With the engine looking like this just before I removed it from the frame,it is easy to see how much work is still needed before I could even begin to think about booking the Chunnel

http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160225_161854_zpsskqrvz93.jpg~original

But,to make it easier to drop the engine I really needed to remove the complete exhaust system.Except that the downpipe flanges were seized in place onto the studs,where years of corrosion between steel and ally had done me no favours Thumbs Down

http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160225_161755_zpspzzmpnkv.jpg~original
http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160225_161816_zps4kxgnseh.jpg~original

So it was easier to unbolt the lower frame rails and to leave the downpipes in situ so that I could seperate the engine from the frame.Then,while the frame was being welded and plastic coated,I could carry on with sorting the engine.Or that was the plan Shocked

http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160311_163538_zpswu8mnmy0.jpg~original
http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160311_163610_zpslx6rtzlu.jpg~original
http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160322_141153_zpsvnybl4lz.jpg~original
http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160322_141201_zpsk1xrglju.jpg~original
http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160322_141212_zpsysnvuadu.jpg~original

Some of the exhaust stud nuts came undone with ease.The others just sheared off flush with the flanges.I made up my mind at this stage to replace the ally flanges with some better thought out replacements,so I was not that bothered about cutting off those ally flanges that were corroded in place.Lots of heat and Plus-Gas made absolutely no difference and I had to resort to cutting them off with a hacksaw by hand,as the air driven hacksaw that I bought was of no use whatsoever Confused

http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160322_141235_zpsc4qw25ux.jpg~original
http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160322_141224_zpsvzutg9ym.jpg~original
http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160322_170235_zpslyrqcunl.jpg~original
http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160322_170244_zpsdeojbdc7.jpg~original
http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160322_170256_zpstkqzo1zz.jpg~original
http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160322_170318_zps78tqvyjy.jpg~original

With the engine inverted it was much easier to attack the flanges and to bring into play the various tools that I had lined up to get the downpipes off

http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160322_170355_zps4xmr3on4.jpg~original
http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160322_170405_zpsmaadkgys.jpg~original

After much hacking and the application of Plus-Gas and direct heat,I ended up with a pile of ally scrap

http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160414_130134_zpsx9h4cppk.jpg~original

But at least the engine was free of the exhaust

http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160414_130124_zpsywq11uo5.jpg~original
http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160414_130149_zpsreurgcll.jpg~original

But the corrosion that I found was worse than expected once I was able to see the sump pan better

http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160414_130202_zpsgoinouir.jpg~original

This I was able to clean up without having to remove it from the engine,especially as the gasket was not leaking

http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160418_134502_zpsaxbncycj.jpg~original
____________________
Just talk bikes.What else is there?

Always have a 'Plan B'


Last edited by Fizzer Thou on 20:16 - 12 Feb 2018; edited 1 time in total
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Fizzer Thou
World Chat Champion



Joined: 06 Aug 2011
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PostPosted: 21:09 - 06 Oct 2016    Post subject: Reply with quote

Time on my hands now that the nights are getting darker earlier,so time to update this post.

In order to drop the engine out of the rusted frame I had to undo several Allen bolts holding the lower frame rails to the lower part of the main frame.One on each side came undone okay,but the others either sheared off or the recess for the Allen key just rounded off.This was proof in itself that they had never been undone in the life of the bike Brick Wall

http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160324_130138_zpstbmr462u.jpg~original
http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160324_130129_zpsgj0go8w1.jpg~original

Luckily,when my friend did the welding of the corroded hole with a plate,he was able to weld on a bolt so that the seized stub could be removed.Then it was a simple thing to run a tap through the hole so as to clean up the thread.The pics above are after the stubs have been removed.

The welded patch worked a treat and it does not show once plastic coated

http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160324_130153_zpse2lae0pb.jpg~original

So now I have the welded frame I taped up the areas that would show the plastic coaters where I did not want it.

http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160331_162929_zpsxvx7p5pv.jpg~original

Together with several other parts they were shipped off to a place just the other side of Brands Hatch Thumbs Up

http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160331_163011_zps5jbvzo9b.jpg~original

I had also bought a lighter/stronger ally bottom yoke that would support the front forks better than the standard steel yoke

http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160405_211041_zpsowowr3an.jpg~original

With the engine seperated from the lower frame rails and the centre stand cleaned up,the intention was clean them up and then black Smoothrite Hammerite them myself,rather than have them plastic coated, as the heat in the curing oven might damage the rubber engine mounts

http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160322_141315_zpswpurtrva.jpg~original
http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160322_141258_zpshdejyn3d.jpg~original

By now the boxes of bits and pieces were full to overflowing Shocked

http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160322_141340_zpsujz4q3j8.jpg~original

With the sub-frame placed to one side I could concentrate on the smaller items,like painting the bits that did not show on the back brake pedal

http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160331_162843_zpswrf6jrsg.jpg~original
http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160405_210938_zpsovfn6o1b.jpg~original

With the exhaust down pipes removed and the sump plate cleaned up,I spent quite a bit of time cleaning up the lower crankcase from years of accumulated filth,especially around the gearbox sprocket area

Next thing was to get as much of the flaking black paint off from between the fins of the cylinder head and the barrel.Luckily the engine was on a work bench so that I could work on it at an easier level than sitting on the floor.So I turned the engine over and supported it with a few blocks of wood and removed the cam cover,where the black paint had flaked off from much off the surface.With plenty of elbow grease it cleaned up okay.I decided not to repaint it as it would not be seen and painted ally is not that good at dissipating heat

http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160420_165147_zpscf4vsor7.jpg~original

With the cam cover removed I could set about measuring the valve clearances,something I was sure had never been done in the life of the bike

http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160418_145400_zpskjdnkg0e.jpg~original
http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160418_145426_zpsugbddvi9.jpg~original
http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160418_145413_zpspzen6gnh.jpg~original

With the shims being located on top of the bucket,the genuine Yamaha shim tool was recommended by several people both on BCF and on the FJOC pages.But which ever way I tried to use the proper tool it would not work,so it was easier to pull the cams so as to swap shims about after I had measured and noted the clearances

http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160425_154154_zpscxz7veoy.jpg~original

I have no problems with realigning the cams after the shims had been sorted,as this is the method by which the shims on the Exup1000 and the R1 are adjusted.Once I had calculated what shims I needed for which valve,I installed one cam at a time and double checked and noted what size shim was where and the resulting clearance

http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160425_154140_zpsmwmaardj.jpg~original

There were plenty of other small jobs to be done,like cleaning up the down pipes and the middle section of the Motad stainless system


http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160428_162518_zpsm4daiefd.jpg~original

And painting the front disc centres

http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160503_094114_zpsnjwye0je.jpg~original

And buying a new air filter.The old one was so blocked you could not see any light through the pleats Shocked

http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160503_222804_zps9tgfswop.jpg~original
http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160503_222845_zpszy1p3ers.jpg~original

I looked quite closely at the two clutch slave pistons.They are quite different,one being the OEM FJ item,the other from the FZR1000R.Can you see the difference?

http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160511_151927_zpsqmq1j7hd.jpg~original
http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160511_151951_zps8fgkhuyj.jpg~original

In my mind,the piston from the FZR1000R is better supported in the bore of the slave cylinder and it fits without any modification and using the same seals,so job done Dance!

And then there were the oil feed pipes to the oil cooler.These were a b****er to separate from the cooler as the steel bolts had corroded where they pass through the tight confines of the connector,so I had to drill them out.....carefully Confused
Once done I cleaned them up using a wire wheel and painted them with the Smoothrite black

http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160604_163848_zps8ct3e38a.jpg~original
http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160604_163932_zpsyxujy7tc.jpg~original
http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160604_163951_zpstjvoxbdc.jpg~original
http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160607_205535_zpspzppmegu.jpg~original
http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160607_205546_zpspeltvkdo.jpg~original

I had specifically chosen an air cooled bike instead of a liquid cooled one because I did not want to have problems with debris damaging a radiator and leave me stranded somewhere,something which has happened to several friends.Although the FJ1200 has an oil cooler,it could still be damaged by road debris.As I make stainless mesh guards for liquid cooled bikes I made up a guard for the FJ

http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160513_162336_zpsgbuljifp.jpg~original
http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160513_162324_zpsmorvlfyz.jpg~original

Then there were the carbs.I had read so many other FJ owners problems with these delicate instruments and their experiences with blocked pilot jets and sticking slides,I looked carefully at every
part that I removed.What I did notice was that neither the float bowl ventilation tubes or other carb breather pipes were filtered.So I sourced a small fuel filter and rearranged how the pipework was situated under the airbox.As it happens,so far so good.Why Yamaha should not choose to do this to the standard FJ when they did it to the FZR1000 I do not know.
Anyway,the float bowls,jets,diaphragms and other easily removable parts were placed to one side while I used plenty of degreaser to wash the bodies of accumulated grease and oil

http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160514_213208_zpsqvu6d1d0.jpg~original
http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160514_213226_zps94krlsht.jpg~original

Luckily the in-line fuel filters were nice and clean and after a quick bath in some carb cleaner they were ready for reinstalling.

http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160515_163324_zpsoifnkm7f.jpg~original

Several people on the various owner sites had mentioned about how difficult it was to adjust the tickover.I just happened to have a remote adjuster in my box of bits of spares from other bikes,so I modified one of the brackets on the carb bank so that I could adjust tickover from the right side of the bikes.Simples Wink

http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160515_173234_zpshribxbg6.jpg~original

This would come in handy when I was ready to balance the carbs as they were bound to be out.
I had also been advised of a better float height that would cure the carb flooding that occurs with the standard float height,so I did this while the carbs were on the bench Thumbs Up

Then I got the frame back from being plastic coated Thumbs Up YAY Dance!

http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160430_104553_zpsln2hhlta.jpg~original
____________________
Just talk bikes.What else is there?

Always have a 'Plan B'


Last edited by Fizzer Thou on 20:30 - 12 Feb 2018; edited 2 times in total
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Fizzer Thou
World Chat Champion



Joined: 06 Aug 2011
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PostPosted: 22:02 - 11 Oct 2016    Post subject: Reply with quote

With the frame back from being plastic coated,was it just a question of bolting bits back on?

No,not really Rolling Eyes

Each part was looked at carefully and if a better bolt or nut could be used from my boxes of spares then it was sized,cleaned and lubricated before being ofered into place.If the bolt was a bit too long and the original was unacceptable,then I cut it back and then assembled it into place.The bike was not as good as it left the factory and previous owners had employed bike shops to work on it during its previous hard life.Along the way,nuts and bolts had become non-OEM and some were really incorrect.I had sufficient to be able to rectify this.

When I had dismantled the frame and left the engine on the work bench,I had worked out the best way to reassemble the bike.
Firstly,I bolted on the lower frame rails to the engine and then lowered the main frame onto this sub-assembly

http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160430_212441_zpsbjwlc9a6.jpg~original
http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160430_212508_zpswtxbc47n.jpg~original

Many parts were easily bolted back into place with fresh grease and a torque wrench Thumbs Up

http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160512_160941_zpso2clcgmb.jpg~original
http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160512_160929_zps8q6aeacj.jpg~original
http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160512_161054_zps4yhdmusn.jpg~original
http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160512_161001_zpszxifpaab.jpg~original

The shorter length dog bones that I had made 5mm shorter than standard would jack up the back end of the bike by about 25mm

http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160513_161530_zpsdcnoa1g1.jpg~original
http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160513_160918_zpslwctxsqp.jpg~original
http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160512_160913_zps180p4d8d.jpg~original
http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160512_150713_zpsregxmncq.jpg~original

I made up an adapter so that I could use my sport bike front stand

http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160526_212822_zpsayjphuzg.jpg~original
http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160526_212849_zpsbjjdejxr.jpg~original
http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160526_212759_zpsfnuer6rw.jpg~original

This made it a lot easier to fit the front wheel and will enable me to be able to work on the front end a lot easier in the future Thumbs Up

But what I really wanted to do was to modify a spare Exup back wheel that I had in the shed and so I tried the other wheel first so as to see what I would have to expect it to look like

http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160512_161106_zpsr5pdevju.jpg~original

Then I tried the wheel that I was going to actually use on the FJ

http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160513_161449_zpsswiwld9e.jpg~original

This I had already balanced after fitting the new PR3 170/60x17.

http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160526_124257_zpscfbfkg96.jpg~original

I chose this size tyre as I did not see the point of going with a 180/55x17 and then not being able to fit it into place.I have heard of people shoehorning a 190/50x17 onto a 5.5" rim,but I had a feeling that when the bike was on its centrestand,that I would encounter clearance problems not only between the ground and the tyre but also between the tyre and the chain and the guard as well as with the rear brake torque arm.So I preferred to go with the 170,knowing that I would not have a problem with any of these thoughts or with the road holding,which I was later to find had no problems at all Very Happy Thumbs Up

I knew from information that I found on the FJOC forum what was needed to modify a standard Exup back wheel and one of the mods was to shorten the spacer fitted into the rear sprocket carrier.This was easily done on the lathe after making a course cut with a hacksaw Thumbs Up

http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160519_225337_zpse6ajhfsf.jpg~original

But other machining on a lathe was not possible and had to be done by hand.This was very labour intensive and took far longer than I thought Shocked

Luckily I had a spare Exup sprocket carrier as well as the standard FJ carrier,which,to all intents and purposes,are exactly the same.

http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160519_225320_zpszdhwk54d.jpg~original

The vanes needed about 5-7mm be removed,for which I used a band saw

http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160524_175802_zps9u4pvauw.jpg~original

Then the hub needed modifying

http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160524_175741_zpskcmctocj.jpg~original
http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160524_212858_zpsqcikwqcu.jpg~original

Countless dry assembly was tried until I had removed just the right amount of material,as once it is taken off cannot be put back again.At this stage I had not fitted the sub-frame,which was ideal while I was modifying the back wheel.
After quite a few hours I found just the right amount of metal had been filed down and the complete rear wheel assembly and rear caliper mount bracket and torque arm were loosely assembled

http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160525_223548_zpsrpeg9ph8.jpg~original
http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160525_223607_zpsy3khn2i6.jpg~original
http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160525_223709_zpsfzqeayor.jpg~original


And finally

http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160526_112324_zpswxuumgok.jpg~original
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Last edited by Fizzer Thou on 20:35 - 12 Feb 2018; edited 2 times in total
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Mark65
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PostPosted: 03:47 - 13 Oct 2016    Post subject: Reply with quote

Awesome show and tell Thumbs Up
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Fizzer Thou
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PostPosted: 21:42 - 16 Oct 2016    Post subject: Reply with quote

The cleaned carbs were easily bolted in place before the subframe could be fitted as the airbox is supported by tabs.New inlet rubbers between the airbox and the carbs had to be purchased as the originals had perished.The heat shield between the cylinder head and the carbs were a bit of a puzzle,but luckily I had taken lots of pics when being dismantled.I also fitted new throttle cables as I did not want to trust the originals in the middle of Europe.I fitted the cables were on the bench because they are a pig to fit at all times,let alone when the carbs are on the engine

http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160612_164029_zps0mkjyvp5.jpg~original
http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160519_100402_zpsekk7qoil.jpg~original
http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160519_100411_zpscviiyhsd.jpg~original
http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160529_185921_zpsv5dnxe6e.jpg~original

Then on with the subframe Thumbs Up This included the wiring loom,which I had left attached as there was no point at this time in removing it.

http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160528_171156_zpsxif10uxg.jpg~original
http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160528_171203_zpsf124h05h.jpg~original
http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160528_171216_zpsws1mdsn2.jpg~original

Now it is starting to look much more like a bike again Very Happy

http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160528_171231_zpsaxwnq2ek.jpg~original

I had heard from a number of places that the fuel pump was a source of mechanical breakdowns in the middle of nowhere,but,having had no problems with a similar pump as fitted as standard to the Exup1000,I was not going to carry a spare that I had in my box of bits

http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160528_221154_zpscnxorztj.jpg~original

From earlier pics you may well remember the flaking paint on the oil filter housing and the gearbox sprocket cover.These I decided would be far better off stripped of the black paint that was left.I do not think that they look out of place Thumbs Up

http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160529_185819_zpseinf7pgc.jpg~original
http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160529_185805_zpsxyz5xr7b.jpg~original
http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160612_163911_zpssl7ekchu.jpg~original

Then the right side footrest bracket went on and the rear brake line coupled up Thumbs Up

http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160529_185910_zpsxuixfkxb.jpg~original
http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160529_185859_zpsasg3hlmz.jpg~original
http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160616_113355_zps0pz1knun.jpg~original

(apologies for the fuzzy pics Confused )

The same person who made me the 5mm shorter dogbones also made me some new exhaust flanges.The original ally ones were used as a template and some new stainless steel plates were used instead Thumbs Up

http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160531_161944_zpstpmbmfjn.jpg~original

Together with stainless Allen bolts,the downpipes for number one and two cylinders were bolted up

http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160601_224301_zpseyjwb4le.jpg~original

Before I fitted the downpipes for cylinder numbers three and four I refitted the refurbished oil cooler and the supply lines.

http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160612_163648_zpsbccp05xd.jpg~original
http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160612_163714_zps5tti3txn.jpg~original
http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160612_163741_zps6tazlug3.jpg~original
http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160612_163804_zpses7xowq1.jpg~original
http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160616_113419_zps1m8khagd.jpg~original
http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160616_113439_zpshuhmef3a.jpg~original

Next came the hand controls.This was a view that I had not seen for some time

http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160612_164044_zps9kj0bf2u.jpg~original

In amongst the box of CBR1000F bits I had some master cylinders for the clutch and front brake.These were in much better condition than the original FJ1200 ones and they also came with adjustable span levers and it was no problem to rearrange the brake light switch.The internals were cleaned and found to be in really good condition,so on they went,together with some new HEL brake and clutch hoses with black sheathing Cool Thumbs Up

http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160612_164052_zpsk1twmzki.jpg~original
http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160612_163542_zpsh9i1xxop.jpg~original
http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160612_163613_zpsain6js09.jpg~original
http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160612_163836_zpstgwk7f5v.jpg~original
http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160612_164106_zps2elkyaiz.jpg~original

Thanks to yenpowell I had some engine bars to fit.These were plastic coated and came up nice and shiney

http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160616_113407_zpsexchw81k.jpg~original
http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160616_113523_zpslpiltu1b.jpg~original
http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160616_113457_zps1pxnzazz.jpg~original

With the silencers and collector box fitted,it seemed worthwhile to thread the wiring loom into place,fit the fairing sub-frame,rear tail unit and try the fuel tank in place.Looking much more like a bike again Dance!

http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160616_113320_zpseiheoj6g.jpg~original
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Last edited by Fizzer Thou on 20:45 - 12 Feb 2018; edited 1 time in total
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Fizzer Thou
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PostPosted: 22:54 - 18 Oct 2016    Post subject: Reply with quote

Before I could fit the fairing there were several items that needed to be rearranged,like how the sub-frame wiring was attached.It had been such a mess when I dismantled this part of the bike that I thought it would be best to do a trial assembly beforehand.Items like the ignition ECU looked like it would be better if it had some sort of vibration killing rubber spacer,so a square of an old inner tube was cut to shape and tried for size

http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160612_203239_zpsgornmcng.jpg~original
http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160616_113505_zps9ysou3lu.jpg~original

Other relays,control boxes and the clocks were also put into place and secured with zip-ties

http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160612_203213_zpsxnzps8t0.jpg~original
http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160616_113645_zpsxzb5pzzo.jpg~original

With the silencers and the battery in place and the sump filled with 20/50 mineral oil it was time to see if the engine ran

http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160616_113539_zpsynwhresp.jpg~original
http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160616_113342_zpshsoa3a4e.jpg~original
http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160616_113553_zpsixdgi5fb.jpg~original

Key in,switched on,all lights lit up.Pressed button.Turns over many times and the fuel pump primes away,but not even a fart.So I rechecked all of the cleaned connections and seemed okay.But the one connector that I had paid particular attention to was not checked and I continued to get annoyed that it would not start.So I went over ALL of the connectors again with some contact cleaner this time and it fired up the first press of the button.Mrs.Fizzer was there to applaud and plans were made to buy the tickets for the Chunnel Very Happy

Europe here we come Cool Sun Dance!

But first I needed to bolt on the fairing,adjust things,fit the pannier brackets,MoT it,road test it and then pack our bags.Things like removing the stupid 'safety' sticker could wait for another time

http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160616_113624_zpswobdijdq.jpg~original

The bike was a Category D write off because the fairing was damaged after a car knocked the PO off and the bike went down at 0 mph.There are a few scuffs and cracks in the fairing and I will look out for a replacement at some time in the future,but it will not stop us from riding around Europe.

The front sub-frame needed to come off and this was just four bolts that needed removing.Then items like the clocks and headlight could be bolted in place after the fairing was bolted onto the sub-frame.Two bolts are hidden by the screen,which is attached by several small chrome dome head allen screws

http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160616_154547_zpsyqp2gdcj.jpg~original

Then the screen went into place together with lots of small plastic covers

http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160616_185343_zpsmrimxlxa.jpg~original
http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160616_185426_zpsmtuznkuo.jpg~original

Front mudguard,side panels and the horn were easily fitted

http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160617_150511_zpscqn4kova.jpg~original
http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160617_150523_zpsht63levg.jpg~original

Evidence of its previous hard life were easy to see

http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160617_150808_zpsw4axwfmf.jpg~original
http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160617_150745_zpsag5iivmk.jpg~original
http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160617_150721_zpsg3ii5vsn.jpg~original
http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160617_150657_zpsvnk1banb.jpg~original
http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160617_150640_zpsyjis5irt.jpg~original
http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160617_150924_zpslydh2tyw.jpg~original


And so to the MoT station

http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160618_124204_zps6lnspger.jpg~original

Where it passed with no advisories Thumbs Up Very Happy Thumbs Up

http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160618_141416_zpsgx5fhgwx.jpg~original

Before I had a run down to see my brother near Brighton I adjusted the carb balance as the tickover was a bit erratic.The vacuum gauges are easily attached to inlet stubs

http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160627_160917_zpsmjci7a1f.jpg~original
http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160627_160933_zpsswbbl2zv.jpg~original
http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160627_160944_zpshcuwsuhc.jpg~original

With a few adjustments here and there I was able to get a nice even tickover together with an improved throttle response

http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160627_162255_zpsdal87vr6.jpg~original

Then it was taxed on-line and a quick polish in the sun

http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160628_135410_zpsdnodxgvt.jpg~original
http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160625_101621_zpscfu7plim.jpg~original
http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160625_101634_zpsura0enqz.jpg~original

The bike is quite different to the other bikes and I was not sure what to expect.I knew that it was a heavy beasty just pushing the bike around with not much fuel in the tank,let alone with panniers,top box,a tank full of petrol and a passenger.Thank goodness Mrs.Fizzer is not a big person Laughing

After the run down to the coast I returned with a number of issues.One was that the back brake was not that effective,despite the need to bed in the new rear pads.So I removed the rear master cylinder and disassembled it.Having found a split seal on the piston,and finding that a repair kit is priced at 45+vat,I looked at the easier option of borrowing the one off the R1,which is almost exactly the same size

http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160628_091027_zpsurhreuhx.jpg~original
http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160628_091005_zpsn3gy77sl.jpg~original
http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160628_135354_zpstu8nn2kq.jpg~original

The other issue was that I had been told that the engine runs much better with a four degree advance back plate fitted.This mod is better for an engine which is going to run on 95 RON fuel,instead of the minimum 91 specified in the manual.First off I needed to remove the rotor from the end of the crank,so I had to remove the left engine bar and spin off the rotor bolt.This was easily done with a ratchet gun

http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160626_184139_zpsjelvghbp.jpg~original
http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160626_184604_zpsztlr35gs.jpg~original

Once the mount holes were elongated by the required amount using a small needle file,the left side was reassembled.Another issue that might be important in the event of an off might be the close proximity of the engine bar to the timing cover,but for the moment I was not going to worry too much

http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160617_150835_zps0fg3py3g.jpg~original

The right side crank end cover was a bit tighter though Shocked

http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160617_150537_zps7ozqnot3.jpg~original

The final work that needed doing was to make up some brackets to fit the pannier brackets to.I did not get these with the other parts,but luckily I was shown some photos of how things should bolt up.With much elbow grease utilised things began to take shape,but it would take several days to get right,considering what it was going to have to carry

http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160629_150751_zpsuckunwjz.jpg~original
http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160629_150803_zpsngrftltk.jpg~original
http://i1073.photobucket.com/albums/w384/Rhencullen5/FJ1200/20160626_104810_zpsojxi1edt.jpg~original

All too quickly the 1st July was upon us and we found ourselves on the Chunnel train

http://i1073.photobucket.com/albums/w384/Rhencullen5/Europe%20Tour%202016/20160701_101247_zpsuts5ntr8.jpg~original

The bike ran like it should have done,if only it had been looked after better.But I was glad that I had taken the time to rebuild the bike as I did,otherwise I am sure that something would have gone wrong.

Our first Euro tour is here

http://www.bikechatforums.com/viewtopic.php?t=316052

Thank you to all those who made comments Smile Thumbs Up
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Last edited by Fizzer Thou on 21:35 - 12 Feb 2018; edited 2 times in total
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pompousporcup...
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PostPosted: 10:22 - 20 Oct 2016    Post subject: Reply with quote

fantastic work that Thumbs Up
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Suntan Sid
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Joined: 07 May 2009
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PostPosted: 19:16 - 20 Oct 2016    Post subject: Reply with quote

That's an epic build and an epic thread.
Couldn't see a lot of the pics on my ipad but finally got to see 'em!
A massive effort with fantastic results! Thumbs Up Karma
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fatjames
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PostPosted: 15:49 - 21 Oct 2016    Post subject: Reply with quote

Great show and tell. Thanks for sharing this, this thread has made my Friday afternoon in work much much better!
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Kris
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PostPosted: 15:57 - 21 Oct 2016    Post subject: Reply with quote

As above, great work and awesome thread! Cool Thumbs Up

Thanks for sharing.
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chickenstrip
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PostPosted: 17:49 - 21 Oct 2016    Post subject: Reply with quote

Nicely done, and well documented - almost feel I could have a crack at similar myself after reading through that (no chance! Laughing ). Good to see a useful old Yam like this brought back to life, and then used as intended Thumbs Up

Now, time to write up the rest of that Euro tour! Smile
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nitrosurf
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Joined: 18 Jun 2010
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PostPosted: 20:40 - 21 Oct 2016    Post subject: Reply with quote

Excellent write up, very impressive. Nice to see a bike like that given a new lease of life.


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Pigeon
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PostPosted: 21:07 - 21 Oct 2016    Post subject: Reply with quote

Herculean effort and fantastic thread!



Nice bit of contributions from other BCF folk too (in terms of parts/tools) Thumbs Up
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The last post was made 2 years, 50 days ago. Instead of replying here, would creating a new thread be more useful?
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