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General Category => FJ Project Writeups => Topic started by: Urban_Legend on September 18, 2017, 05:00:41 AM



Title: Sparkles version 2.0
Post by: Urban_Legend on September 18, 2017, 05:00:41 AM
Hey all.
A week or two ago I put a post about how a 1 hour job to replace the intake boots had escalated into something so much more. So in brief, changing the boots l, turned into giving the motor some fresh paint, which then turned into giving the bike a respray. :Facepalm:
The general plan is to paint the bike (84 FJ1100) in an OEM style, but not OEM colours.
With the bike stripped of all of its bits, I have set about sanding back only 2 years of my sins.

Gravel Rash on the right side of the fairing
Brake fluid ruined paint on the left side of the fairing from an in noticed clutch MC leak.
Stuffed paint on the fuel tank from a very botched job of applying protective film. Blah blah blah.
You get the picture. The paint on the bike got a hard time.
I now have the panels and tank rubbed back and have started applying the undercoat. The hard bit is stopping myself from rushing. As we have all heard. Its all in the preparation. Shown below. Is my starting point, where I am up to now and where I hope to end up. More updates to follow
Mark


Title: Re: Sparkles version 2.0
Post by: Urban_Legend on September 28, 2017, 04:59:48 PM
Hi

Bit of an update on my progress.
Ihave spent every evening for the last week and a half on sanding back paint prep and under coating all of the bike cosmetic bits. And last night I finally got to start putting colour down. There are a few bits I am not entirely happy with but time is against me. I have to return the vehicle I borrowed from my father this weekend and the bike will once again be my main form of transport. So it needs to be done. At least I have the paint codes so touch ups can be done as time permists at a later date.
First colour down is the Silver, and the bike is now getting mashed up for the blue to go down, and I should have all the decals ready this afternoon. Getting the lines right for the blue was a bitch. :dash1: but with lots of measuring and redoing and looking, i am happy with the line up. less the +/- 2mm tolerance.
I am usung Acrylic paint
There is also a "NEW" cover for my gauges coming (thanks RoverFJ1200 - Richard) so hopefully that will be fitted in the next few days too.

Mark


Title: Re: Sparkles version 2.0
Post by: Urban_Legend on September 30, 2017, 05:20:05 AM
Had a good day putting more colour on. Need to rub back tomorrow with some 2000 grit and apply the decals then its clear coat time. Nearly there.


Title: Re: Sparkles version 2.0
Post by: Urban_Legend on September 30, 2017, 05:25:03 AM
Few more pics


Title: Re: Sparkles version 2.0
Post by: Urban_Legend on October 01, 2017, 05:57:32 AM
Huge day on the bike today.
1) Rubbed back the colour ready for clear coat.
2) Applies full set of decals
3) Applied 5 coats of clear
4) did the coil relay mod
5) polished a few bits and pieces (bar ends and the plate that connects the front fender pieces)
6) put most of the bike back together.
The fairing will have to wait a few days while I wait for a new gauge cover.
The paint will need a cut  and polish, but I am really happy with how it is turning out.
Mark


Title: Re: Sparkles version 2.0
Post by: Country Joe on October 01, 2017, 06:24:25 AM
 :good:
Mark,
 That looks awesome!! Those colors look like Yamaha should have offered them during the production run.
Joe


Title: Re: Sparkles version 2.0
Post by: Urban_Legend on October 03, 2017, 06:18:21 AM
And there we have it ladies and gentleman. I was hoping to be done in daylight hours, but had a little set back. But now it is all done, except for the test ride.

This transformation took me 3 weeks, with all work done by me in my garage. I am really happy with the result.


Title: Re: Sparkles version 2.0
Post by: FJmonkey on October 03, 2017, 07:56:12 AM
Looks like a job well done.


Title: Re: Sparkles version 2.0
Post by: PaulG on October 03, 2017, 08:29:34 AM
I can't imagine what it would cost to get a "professional" to do all that work. Yes they would have taken less time but would it be any better in your eyes? Nice colours you picked and a great inspiration too.  :good2:


Title: Re: Sparkles version 2.0
Post by: Pat Conlon on October 03, 2017, 09:18:35 AM
That's beautiful Mark! I like that color combo.  I would look at adding some blue or silver spots, for the front calipers, the red calipers look out of place.

You should be proud. Well done laddie!    Pat


Title: Re: Sparkles version 2.0
Post by: Firehawk068 on October 03, 2017, 10:08:15 AM
Wow!
I really like that color combo.
Very nicely done!  :good2:


Title: Re: Sparkles version 2.0
Post by: Sparky84 on October 04, 2017, 12:54:06 AM
Mate that Looks Good !!
Looks So much Faster and Lighter  :good2:

(But not as fast as the Red & White  :biggrin:)

3 weeks is a pretty good turn around, I'd be stoked with that.

Cheers
Alan


Title: Re: Sparkles version 2.0
Post by: Urban_Legend on October 04, 2017, 05:55:13 AM
Thanks guys
 Yes three weeks was short, but the bike is my main transport, so needed it back on the road. I have learned a lot, and I know how to fix up some of the mistakes.  :dash1:
Planning is under way for a further improvement. Same colour scheme and layout, but not rushed. I have an other fairing that will require some substantial fibreglass work to restore all of the bits the PO cut off it. I also would like a 1200 tank. I like the aviation style cap and it will allow me to use a tank cover and clip on tank bag. Also get some less banged up side covers and I can respray the lot at my leisure. That's the plan anyway. Always room for improvement.

Mark


Title: Re: Sparkles version 2.0
Post by: Sparky84 on October 04, 2017, 06:16:02 AM
I also would like a 1200 tank. I like the aviation style cap and it will allow me to use a tank cover and clip on tank bag..

That's something I'd like to do also, instead of using a magnetic one, less chances of scratches.

But then you don't have to worry about those, 1weekend would see you respray the scratches out  :good:

Cheers
Alan


Title: Re: Sparkles version 2.0
Post by: Urban_Legend on February 20, 2018, 12:29:57 AM
Haven't posted about the bike for a bit, so here is an update. I finally got around to giving the paint a rub back with 2000 wet/dry to eliminate most of the orange peel, then machine polished to bring out the shine. I must say that I amost pleased with the results. I have also acquired two low mileage motors, a 3cv 1200 with 30000km an an 1100 with 60000km,for the next stage. My current motor has a bad second gear issue and a tired starter and possibly a dodgy reg/rec. The plan is to put the 1200 on as an interim and build a good 1100. (Possible 1300) from the 2 1100s.
More to come
Mark


Title: Re: Sparkles version 2.0
Post by: racerrad8 on February 20, 2018, 08:50:34 AM
Mark,

If you are thinking of going big bore, you'll need to start with the 1200. The block is required for those big bores.

Randy - RPM


Title: Re: Sparkles version 2.0
Post by: red on February 20, 2018, 12:08:29 PM
Mark,

That's sure looking good, from here . . .  :biggrin:  I'm curious about what was done to the engine fins and case, to get that deep shine seen in  IMG_20170909_123243.jpg.

Man, it took forever to load those pix.  Do you really need to post pix that are 57" (146cm) tall, and 2~3 Megs?  Kinda rude, I mean, not everybody has an ultra-fast Internet.  Most image programs can SCALE an image to a reasonable size, with a much smaller file size.  I use GIMP, which is free here.  Your image was 57" (146cm) tall, and 3.15Meg in size.  I SCALEd that image to 6.6" (17cm) tall, and the file size then was 146kb.  That is about 5% of what you sent, by file size.  Do you really see that much difference between these two images?


Title: Re: Sparkles version 2.0
Post by: Urban_Legend on February 20, 2018, 02:18:07 PM
Sorry about the file size. :sorry: images sent directly from my phone.
The shine on the engine is from VHT gloss engine enamel. Prep was degrease, pressure wash, wipe over with prepsol, mask and paint.


Title: Re: Sparkles version 2.0
Post by: red on February 20, 2018, 03:32:40 PM
Sorry about the file size. :sorry: images sent directly from my phone.
The shine on the engine is from VHT gloss engine enamel. Prep was degrease, pressure wash, wipe over with prepsol, mask and paint.
Mark,

Thanks for that.  I have only seen VHT flat colors before.  Lookin' good!     :yes: 

Most phones have a default image size, but maybe you can adjust Settings on that issue.  Your phone maker or seller can probably help, or there may be a manual on-line for that unit.  You might want large files for personal stuff, but it's not needed for the Internet.  'Preciate your concern.


Title: Re: Sparkles version 2.0
Post by: Urban_Legend on February 20, 2018, 03:42:41 PM
Cool. Thanks Red. Will try to rectify.
Mark


Title: Re: Sparkles version 2.0
Post by: Urban_Legend on February 20, 2018, 03:44:53 PM
Test shot.


Title: Re: Sparkles version 2.0
Post by: Urban_Legend on February 20, 2018, 03:47:33 PM
That's as low as my phone goes Red. Much quicker upload. Thanks for your advice.


Title: Re: Sparkles version 2.0
Post by: fj johnnie on February 20, 2018, 04:29:37 PM
 Phenomenal job. Excellent color choices as well. It's so nice to see other people loving their FJ's!!


Title: Re: Sparkles version 2.0
Post by: red on February 20, 2018, 05:24:28 PM
That's as low as my phone goes Red. Much quicker upload. Thanks for your advice.
Mark,

Faster at this end, too.  Thanks.

How 'bout if I mail you my FJ, for the  next project?  Lemme see, cost of postage from the USA to Australia . . .  umm, never mind.    :biggrin:   


Title: Re: Sparkles version 2.0
Post by: Urban_Legend on February 20, 2018, 06:07:20 PM
The sad thing is, the day after i got the 1200 motor, a 91 1200 came up for sale minus its motor....and i no longer had the money availiable to purchace it. Would have been perfect.

Bugger

Mark


Title: Re: Sparkles version 2.0
Post by: Urban_Legend on April 02, 2018, 07:05:17 AM
Work has started on the motor swap. I managed to remove the old motor today (on my own) and have started prep on work on the "new" low mileage 1200 motor.

  I learned that the trick to getting the motor out is to get some elevation with the frame so the you have wriggle room for trolley jack to lower the motor enough out the side of the frame.

Will do some other bits of tidying up while it apart.

Pete (Oldktmdude) will be receiving my carbs soon to get them sorted. Hopefully it will all be back together in a few weeks so I can get my Kookaloo on.


Title: Re: Sparkles version 2.0
Post by: Urban_Legend on April 08, 2018, 04:25:47 AM
Been a big few days here at the Oily Rag Garage. Got all (2x1100's and 1x1200) degreased and pressure cleaned. Polished a few bits, and painted the 1200. This afternoon was spent installing it. Next job is to swap the clutch and detent kit over from the old motor and do the ignition advance mod.

Pete (Oldktmdude) got my carbs on Thursday and has checked them over. He fiddled with the jetting a bit and tested them on his bike. He says they worked well with no sign of the issues I was having. He suggested that maybe one of my cams had slipped a tooth which would possibly lead to some of the performances issues the bike was suffering. Will check the hypothesis out.


Title: Re: Sparkles version 2.0
Post by: oldktmdude on April 08, 2018, 04:57:47 AM
   Looking good Mark. Your carbs will be in tommorrow's post. When you do the ignition advance, make sure you file the correct side of the holes.
You need to rotate the ignition plate clockwise, in other words, opposite to the direction that the engine runs. File out to the outer edge of the washer shadow.
Another good tip is to replace the shit 6mm phillips head screws, that hold the ignition plate in place, with some s/s socket head cap screws.   
Good luck with the new engine.
Regards, Pete.


Title: Re: Sparkles version 2.0
Post by: Urban_Legend on April 08, 2018, 05:25:42 AM
Thanks Pete. Can't wait to get it all back together. Hope she all just falls into place. I know I will need to replace some electrical connectors. Dog ate one of them. Otherwise all is looking good.

Mark


Title: Re: Sparkles version 2.0
Post by: FJ_Hooligan on April 10, 2018, 09:59:02 AM
It couldn't hurt to check the cam timing since it takes all of 3 minutes once the cam cover is off. 

However, the probability that a cam has "slipped a tooth" is remote unless you've had the cam out and reinstalled it incorrectly.  To jump a tooth, the cam chain would have to be horribly stretched out and the cam chain adjuster fully deployed and totally worn out.  I just don't see it as a possibility.  Additionally, I've never read anyone reporting that their cam had slipped a tooth.

If it was an old small block Chevy with the nylon cam gear teeth that have been worn to nubs, then it's possible.  But not on a chain driven FJ cam train.


Title: Re: Sparkles version 2.0
Post by: Urban_Legend on April 10, 2018, 04:07:56 PM
Hey FJ Hooligan
Skipped a tooth may have been the wrong expression. You are right it is more likely that the cam chain has stretched and the timing is out. I just used the first expression that came to mine when trying to describe the issue. I hope to be able to investigate it further tonight.
From the info I have. The 1100 motor has about 90k km on it. It was from a bike that was stolen and then recovered. I know that it had been given a hard time whilst in the hands of the offenders. I now have confirmation that my carbs are NOT the issue ( installed on another bike and it ran fine) with my lack of power and running issues. So we came back to the Cams and Timing.

Mark


Title: Re: Sparkles version 2.0
Post by: oldktmdude on April 10, 2018, 04:16:01 PM
   Thanks Mark, when I made the comment about the cam timing being out by 1 tooth, I was inferring that a previous owner had mis-timed
the cam during some work being done to it. You mentioned that the bike hadn't performed well since you bought it so obviously it had a problem
since day one of your ownership. Alf's 1100 had very similar issues to yours and the problem turned out to be a miss-timed cam.
   Regards, Pete.


Title: Re: Sparkles version 2.0
Post by: Urban_Legend on April 15, 2018, 12:59:13 AM
I spent the last few days swapping various bits from the 1100 to the 1200 motor. Swapped the clutch (1100 one is new) and the detent kit. Also had to swap the ignition pick up for the 1100 over to match the CDI.

Got her all buttoned up. Now Sparkles is now officially a 1200. I took her for a 20km shake down ride. Took her gentle for the first few blocks listening or any noises. Nope none. Actually it was a bit unnerving how quite this motor is compared to the old 1100. Not starter chain rattle. Quite tappets. Got out of town and fed it to her, a bit tentatively at first, but then I gave her a fist full in second then third.......wow holy crap. There's my missing 30hp. Zooming past 140 in third right out to red line. I must say it is so nice not having to granny shift out of second. The other thing is this motor is so smooth compared to the 1100. Glanced at the speedo at one stage and the needle was very quickly heading towards 200. Crap. Slow her down. Home again after 20km no leaks and nothing fell off. Big smile. Kookaloo.


Title: Re: Sparkles version 2.0
Post by: Sparky84 on April 15, 2018, 02:24:06 AM
I spent the last few days swapping various bits from the 1100 to the 1200 motor. Swapped the clutch (1100 one is new) and the detent kit. Also had to swap the ignition pick up for the 1100 over to match the CDI.

Got her all buttoned up. Now Sparkles is now officially a 1200. I took her for a 20km shake down ride. Took her gentle for the first few blocks listening or any noises. Nope none. Actually it was a bit unnerving how quite this motor is compared to the old 1100. Not starter chain rattle. Quite tappets.

No noises, quiet tappets, NO starter chain rattle !!!!!!!!!!!! WHAT have you done Mark?  :nea:

Its not a FJ Without those. 


Title: Re: Sparkles version 2.0
Post by: Urban_Legend on April 15, 2018, 03:10:59 AM
No noises, quiet tappets, NO starter chain rattle !!!!!!!!!!!! WHAT have you done Mark?  :nea:

Its not a FJ Without those.  

I know. Thought I must have stuffed up and put a Suzuki motor in it for a bit, then realized it was still running.


Title: Re: Sparkles version 2.0
Post by: fj-f3a on April 16, 2018, 06:11:41 PM
Whats OEM?

Owner Engineered Modifications.


Title: Re: Sparkles version 2.0
Post by: Urban_Legend on April 16, 2018, 07:36:03 PM
I like your thinking.
Found out today the NSW  bike rego has changed. No longer done by engine capacity. Flat fee for all bikes. Only green slip is different now. I do have to get a blue slip for Sparkles now with the different motor in it.

Mark


Title: Re: Sparkles version 2.0
Post by: Pat Conlon on April 16, 2018, 10:08:47 PM
Congrats Mark :good2: She is beautiful and lucky to have you as her owner.

Pat


Title: Re: Sparkles version 2.0
Post by: Urban_Legend on April 17, 2018, 12:21:34 AM
Thanks Pat

I need to get myself another project so i can leave this bike alone.


Title: Re: Sparkles version 2.0
Post by: Old Rider on September 21, 2018, 01:55:45 AM
You have done a superb job Mark looks very nice.I know how much work laying behind a result like this because i have done exatly the same work last summer when i repainted mine.
First you think that the job is going to be quick but then there is sanding filling out chips with putty sanding cleaning priming sanding priming sanding basecoat topcoat clearcoat decals clercote sanding clearcoat wetsanding and polishing cleaning  and hours of masking . :morning1:


Title: Re: Sparkles version 2.0
Post by: Tuned forks on September 22, 2018, 11:48:49 AM
I agree with Old Rider, paint jobs often take way longer than expected.

Urban_Legend, that VHT engine paint looks outstanding.  Such gloss!  Congrats on being a 1200 convert.  I only heard my valvetrain noise after adjusting the valves and getting my ears down next to the cylinder head.  Great work, I agree you need another project.


Title: Re: Sparkles version 2.0
Post by: Urban_Legend on September 22, 2018, 08:24:53 PM
Thanks all. You will all be happy to know that I have left the bike alone since the great case splitting debacle. Just enjoying riding it to her new limits. Been exploring the outer edge of the tyres for the first time ever. Only job to do is to finish fixing the right side air scoop and reinstall.
I have found a nice little 92 FJ project bike from a mate. Just some fine details, like payment and transportation, but at least he isn't in a rush to move it out of his shed.
With Sparkles being a long way from standard, my plan is to keep this one fairly original.


Title: Re: Sparkles version 2.0
Post by: Troyskie on September 23, 2018, 01:44:41 AM
Mark are you joining the Ambulance Brigade? Or are you going to give Xray a run for the chook?  :drinks: :drinks:


Title: Re: Sparkles version 2.0
Post by: Urban_Legend on September 23, 2018, 03:44:57 AM
It's Xray's 92 that I am going to buy, so no ambulance for me


Title: Re: Sparkles version 2.0
Post by: Troyskie on September 23, 2018, 03:51:15 AM
Chook time!