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General Category => FJ Project Writeups => Topic started by: MOTOMYSZOR on March 01, 2016, 12:01:59 PM



Title: FJ1200 ABS '91 from damp shed - Moditus attack story
Post by: MOTOMYSZOR on March 01, 2016, 12:01:59 PM
It was September 2014 when I decided that I will buy my first Yamaha.

She was in pretty bad condition: rust, dust and spider webs. But despite that appearance, after few minutes I got strange feeling that She can be nice bike for me.

Now I know that was the moment when moditus bug jumped straight into my brain  :crazy:

I have spent hours on carburettors an valve regulations, cleaning and checking all bike from back to front:

(http://fjowners.com/gallery/9/4406_01_03_16_11_43_47.jpeg)

(http://fjowners.com/gallery/9/4406_01_03_16_11_45_02.jpeg)


That is first photo where my FJ looks decent:

(http://fjowners.com/gallery/9/4406_01_03_16_11_42_24.jpeg)

And then I found FJowners forum and section: MODIFICATION .....

And that was beginning of MODITUS ATTACK  :crazy: :crazy: :crazy: :wacko2: :wacko2:

Previous owner installed few extras:
- full set of Givi boxes
- rear shock absorber Hagon (red spring) + progressive front
- engine bars

And from that time I added few other......




Title: Re: FJ1200 ABS '91 from damp shed - Moditus attack story
Post by: FJmonkey on March 01, 2016, 01:32:56 PM
A fork brace will stiffen the forks up and reduce the chances of your front fender tabs breaking.


Title: Re: FJ1200 ABS '91 from damp shed - Moditus attack story
Post by: MOTOMYSZOR on March 02, 2016, 01:12:47 PM
First my ,,small" mods:

Front braided brake lines and FZ8 gold brake callipers:

(http://fjowners.com/gallery/8/4406_21_04_15_10_26_02.jpeg)

Engine temperature meter and volt meter:

(http://fjowners.com/gallery/8/4406_18_04_15_2_24_17.jpeg)

14 mm clutch MC from FJR and brake MC from Fazer 600:

(http://fjowners.com/gallery/8/medium_4406_03_05_15_11_50_15_1.jpeg)

(http://fjowners.com/gallery/8/medium_4406_03_05_15_11_50_14_0.jpeg)


I also installed CBR mirrors, Ignition coils relay, GPS holder.....




Title: Re: FJ1200 ABS '91 from damp shed - Moditus attack story
Post by: MOTOMYSZOR on March 02, 2016, 01:20:56 PM
In middle of 2015 I swapped front rim for FZR 1000 rim.

This is list what was needed for my ABS model:

- front FZR1000 wheel - in my case with 17 mm axle
- set of brake discs - can be from various models like non-ABS FJ or many other 298 mm discs
- 6203 LHA Ball Bearing.  Size 15x40x12
- non-ABS 15mm inner spacer. Spacer from my ABS model is to short.
- non-ABS collar spacer (between fork and wheel bearing) because ABS one is to short again.
- FJ1200 15mm axle and speedo driver.

(http://fjowners.com/gallery/9/4406_02_03_16_1_18_15.jpeg)

(http://fjowners.com/gallery/9/4406_02_03_16_1_19_12.jpeg)

(http://fjowners.com/gallery/9/4406_02_03_16_1_17_34.jpeg)



Title: Re: FJ1200 ABS '91 from damp shed - Moditus attack story
Post by: MOTOMYSZOR on March 02, 2016, 01:28:10 PM
And then the biggest mod: rear wheel, brake system and swingarm from Fazer1000:

(http://fjowners.com/gallery/9/4406_03_09_15_11_28_38.jpeg)

(http://fjowners.com/gallery/9/4406_03_09_15_11_29_28.jpeg)

(http://fjowners.com/gallery/9/4406_03_09_15_11_29_02.jpeg)

Together with Delkevic exhaust rear end looks nice:

(http://fjowners.com/gallery/9/4406_18_02_16_8_00_28_0.jpeg)

(http://fjowners.com/gallery/9/4406_18_02_16_8_00_28_2.jpeg)



Title: Re: FJ1200 ABS '91 from damp shed - Moditus attack story
Post by: Pat Conlon on March 02, 2016, 05:33:14 PM
Karol, absolutely wonderful job :good2:

You should be proud....marvelous! 

You will notice the improvement with modern 17" tires along with those R-1 brakes

Cheers...again well done!


Title: Re: FJ1200 ABS '91 from damp shed - Moditus attack story
Post by: MOTOMYSZOR on April 12, 2016, 02:28:33 PM
I started work on a new mod: gear indicator
So far I upgraded neutral gear sensor.

First I had to find specific points on switch where should I drill.
For  create imprints, I used plasticine:

(http://fjowners.com/gallery/9/medium_4406_12_04_16_2_03_35_1.jpeg)

Important part is to use guide screws:

(http://fjowners.com/gallery/9/medium_4406_12_04_16_2_03_35_0.jpeg)

As a connectors I used M3 allen grub screws:

(http://fjowners.com/gallery/9/medium_4406_12_04_16_2_03_35_2.jpeg)

top:

(http://fjowners.com/gallery/9/medium_4406_12_04_16_2_03_35_3.jpeg)

From inside:

(http://fjowners.com/gallery/9/medium_4406_12_04_16_2_03_36_4.jpeg)

First fittings:

(http://fjowners.com/gallery/9/4406_12_04_16_2_21_37.jpeg)

I used conductivity meter to regulate, how deep those screws should be screwed to get good contact with gear shaft. On end I used glue gun to seal everything...

half job done :)





Title: Re: FJ1200 ABS '91 from damp shed - Moditus attack story
Post by: MOTOMYSZOR on April 14, 2016, 08:37:56 AM
Job done:



Title: Re: FJ1200 ABS '91 from damp shed - Moditus attack story
Post by: MOTOMYSZOR on September 02, 2016, 06:16:16 AM
Time for front suspension upgrade and rebuild......
Today I received Race Tech springs and emulators.

And already i have problem:

(http://fjowners.com/gallery/10/4406_02_09_16_6_13_47.jpeg)

As You can see on photo original RT washer is small enough to cover most of oil flow area in emulator..... Is that OK?

And one more question: I got yellow and blue springs for emulator: which ones suit better for FJ?


Title: Re: FJ1200 ABS '91 from damp shed - Moditus attack story
Post by: MOTOMYSZOR on September 02, 2016, 01:03:02 PM
It is too late to edit post.....

I discovered that no washer is used under spring......  :blush:

But still..... spring has this same size as washer and will greatly block oil flow....


Title: Re: FJ1200 ABS '91 from damp shed - Moditus attack story
Post by: ct7088 on September 02, 2016, 09:53:08 PM
There is a calculator according to your weight on Race Tech FJ 1200 page. 190 lbs gives a answer of .934kg/mm with the suggestion to use the number that is closest which is .95kg/mm
Chris


Title: Re: FJ1200 ABS '91 from damp shed - Moditus attack story
Post by: MOTOMYSZOR on September 15, 2016, 12:50:14 PM
I Have big problem.....

Because Hagon progressive spring was so hard suspension worked only on half way...... the upper fork part was unused and rusted...... When I touched it chrome just fell off.....

So if now suspension will travel all length available (150mm) seal will last for few Kilometres.....

I don't know what to do now...... Or actually I know. Have to buy forks in good condition.....



Title: Re: FJ1200 ABS '91 from damp shed - Moditus attack story
Post by: MOTOMYSZOR on September 24, 2016, 11:51:46 AM
I found front suspension from 95 FJ1200 in really good condition on eBay.... and already I got everything done.  :rofl:

My setup:

 -Race Tech springs 0,95 kg/mm
 -Fork Oil 15W motul
 -Oil level - 130mm ( with emulators in)
 -15mm preload
 
I used yellow (hard) springs in emulators, set at 2 turns in. And for me it is to hard......

When I will have a time I will try blue springs and lower oil level (150mm)


Title: Re: FJ1200 ABS '91 from damp shed - Moditus attack story
Post by: MOTOMYSZOR on October 16, 2016, 05:16:56 AM
I think I finished front upgrade.

Final setup:
 -Race Tech springs 0,95 kg/mm
- emulators with blue springs. 2 turns in
 -Fork Oil 15W motul
 -Oil level - 140mm ( with emulators in)
 -20mm preload

Now I have full control on every corner or roundabout. I notice less vibration while riding. And my chicken strips are smaller now:


Title: Re: FJ1200 ABS '91 from damp shed - Moditus attack story
Post by: MOTOMYSZOR on November 02, 2018, 02:20:44 PM
After few situations when me or my friends have heard: SORRY..... I DID NOT SEE YOU I decided.....

Time for CHRISTMAS TREE mod..... I don't care about how it looks any more. I want to be visible....

First auxiliary lights, I used pair of 125W CREE lights:

125W CREE LED lights (https://www.ebay.ie/itm/2pcs-125W-CREE-U5-LED-Headlight-Motorcycle-Driving-Fog-Spot-Bulb-Light-Switch/253150624946?ssPageName=STRK%3AMEBIDX%3AIT&_trksid=p2060353.m2749.l2649)

(http://www.fjowners.com/index.php?action-gallery;sa=view;id=10998)

To install them I used bike handle mount:
 Bike handlebar mount (https://www.ebay.ie/itm/MTB-Bike-Handlebar-Extender-Extension-Expand-Mount-Computer-Light-Holder-Bracket/163223011069?ssPageName=STRK%3AMEBIDX%3AIT&var=462431784327&_trksid=p2060353.m2749.l2649)

(http://fjowners.com/gallery/10/4406_02_11_18_2_08_09_1.jpeg)

I mount them on engine protectors:

(http://fjowners.com/gallery/10/4406_02_11_18_2_08_10_2.jpeg)


Part two:

emergency flash lights (https://www.ebay.ie/itm/2X-4-LED-Car-Truck-Emergency-Beacon-Warning-Hazard-Flash-Strobe-Light-Bar-White/273384039405?ssPageName=STRK%3AMEBIDX%3AIT&_trksid=p2060353.m2749.l2649) - I use them in heavy traffic and on motorway when somebody blocking my lane.
 

After huge trouble with finding suitable space I installed them under mirrors:

(http://fjowners.com/gallery/10/4406_02_11_18_2_08_09_0.jpeg)


And to  switch them on and off  (https://www.ebay.ie/itm/Motorbike-Scooter-ATV-LED-Headlight-Headlamp-On-Off-Switch-with-Red-Indicator-LJ/112734370469?ssPageName=STRK%3AMEBIDX%3AIT&_trksid=p2060353.m2749.l2649) I installed this:

(http://fjowners.com/gallery/10/4406_02_11_18_2_08_10_4.jpeg)

I am  very happy with those add ons.....










Title: Re: FJ1200 ABS '91 from damp shed - Moditus attack story
Post by: Tuned forks on November 02, 2018, 07:53:25 PM
Nice work.  Your gauges in the side panel make me think..hmmmmmmm.

Hope to make the FZR wheel swap this winter.  Your front wheel info was helpful.

Joe


Title: Re: FJ1200 ABS '91 from damp shed - Moditus attack story
Post by: MOTOMYSZOR on November 07, 2018, 02:10:20 PM
I added LED headlight bulb:

(http://fjowners.com/gallery/10/4406_02_11_18_2_08_10_3.jpeg)


Its light is much whiter and very bright, and it is much more visible then regular bulb.....

I just need to do night test to check how it will work.

Overall I am very happy with effect.


Title: Re: FJ1200 ABS '91 from damp shed - Moditus attack story
Post by: Millietant on November 07, 2018, 04:23:47 PM
Very interested in this - did you buy a kit?; did you put it together yourself?; what's involved?; where did you buy it from?

Would be good to know  :smile:


Title: Re: FJ1200 ABS '91 from damp shed - Moditus attack story
Post by: Tuned forks on November 07, 2018, 05:37:34 PM
Yeah, yeah, what Dean wrote.^^^^^

Joe


Title: Re: FJ1200 ABS '91 from damp shed - Moditus attack story
Post by: MOTOMYSZOR on November 08, 2018, 03:20:42 AM
Bulb You can get from hundred different shops. I got mine from eBay:

https://www.ebay.ie/itm/32W-White-COB-LED-HID-White-360-Hi-Lo-Beam-H4-Motorcycle-Headlight-Bulb-IP67/263628568627?ssPageName=STRK%3AMEBIDX%3AIT&_trksid=p2060353.m2749.l2649 (https://www.ebay.ie/itm/32W-White-COB-LED-HID-White-360-Hi-Lo-Beam-H4-Motorcycle-Headlight-Bulb-IP67/263628568627?ssPageName=STRK%3AMEBIDX%3AIT&_trksid=p2060353.m2749.l2649)

It comes with H4 socket very easy to install on bulb and then in headlight. Plug and play....

Only one problem: because end of the bulb is bigger rubber cover wont fit properly.....


Title: Re: FJ1200 ABS '91 from damp shed - Moditus attack story
Post by: Ribz0 on December 02, 2018, 07:27:02 PM
What a great read!! You are cleaver well... you know...

With the extra lights.... how does the bike's charging system and battery deal with it all? are there any upgrades to be done there or is the stock stuff ok?

Cheers


Title: Re: FJ1200 ABS '91 from damp shed - Moditus attack story
Post by: Pat Conlon on December 02, 2018, 10:45:14 PM
......Only one problem: because end of the bulb is bigger rubber cover wont fit properly.....

That would be a deal breaker for me.

You gotta keep that headlight housing sealed up, or you will be sorry.


Title: Re: FJ1200 ABS '91 from damp shed - Moditus attack story
Post by: andyoutandabout on December 03, 2018, 09:09:09 PM
Missed this thread originally. Dude, I’ve the same model, a Brit 1991 ABS. Here’s a thing. I heard that the MOT people can give you a really tough time if you remove the ABS and insurance companies take a dim view of brake mods especially (even though we FJ owners know the superior blue dot/gold dot set up). Have you encounter any such grief from the authorities?


Title: Re: FJ1200 ABS '91 from damp shed - Moditus attack story
Post by: Millietant on December 04, 2018, 01:03:20 AM
Missed this thread originally. Dude, I’ve the same model, a Brit 1991 ABS. Here’s a thing. I heard that the MOT people can give you a really tough time if you remove the ABS and insurance companies take a dim view of brake mods especially (even though we FJ owners know the superior blue dot/gold dot set up). Have you encounter any such grief from the authorities?

Yes, insurance-wise, if you don't declare that you've removed the ABS, then your insurance would be invalidated - if the insurance company found out. If you do declare it, some wouldn't insure you and others would hike your premium.

A switched-on MOT tester here would definitely fail the bike for not having a working ABS system, but if the front wheel &brakes had been changed and there was no evidence of any original system, the I wouldn't be an issue.


Title: Re: FJ1200 ABS '91 from damp shed - Moditus attack story
Post by: MOTOMYSZOR on December 14, 2018, 03:17:11 PM
Because headlight bulb takes only 35W and auxiliary light only 15W so there is no danger for charging system and battery.

I declared mods for insurance company. So my bike is officially SPORT MODIFIED ;)

My bike won't fail MOT test..... simply because we don't have MOT tests (unfortunately) for motorbikes in Ireland. And that mean many bikes in dramatic condition on roads.....