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General Category => FJ Project Writeups => Topic started by: aviationfred on August 02, 2021, 10:13:38 PM



Title: 1989 3CV Streetfighter Project
Post by: aviationfred on August 02, 2021, 10:13:38 PM
My Streetfighter project has officially kicked off. Initially all 3 FJ's will be involved with engine and head swaps.  :scratch_one-s_head:
Casper has the damaged engine that needs repaired and rebuilt. That engine will end up in the Streetfighter.  The 1297cc engine has been removed and the head is off. The head from the 1995 has the fresh rebuild with oversize valves. That head will be removed and installed on the 1297cc engine, which will then be put into Casper. The stock head that was pulled from the 1297cc engine will go on the 1995 engine.   :wacko1: :wacko2:

Parts have been ordered have have already started to be delivered.



Fred


Title: Re: 1989 3CV Streetfighter Project
Post by: FJmonkey on August 02, 2021, 10:18:38 PM
Which one gets the "Turbo Encabulator"?


Title: Re: 1989 3CV Streetfighter Project
Post by: Pat Conlon on August 03, 2021, 10:15:25 PM
Lots of burned oil on those pistons…Now would be a perfect time to fix those leaky oil rings or throw those POS Hank Scott pistons away….

Far away….


Title: Re: 1989 3CV Streetfighter Project
Post by: Dads_FJ on August 04, 2021, 07:07:24 AM
Lots of burned oil on those pistons…Now would be a perfect time to fix those leaky oil rings or throw those POS Hank Scott pistons away….

Far away….

I noticed that too, Father Pat knows of what he speaks.  Pat, as I recall didn't you have a similar problem with rings that didn't seat?  Now would be the time to address the issue since it's out of the bike and apart.


Title: Re: 1989 3CV Streetfighter Project
Post by: giantkiller on August 04, 2021, 07:57:27 AM
I have the same problem with my 1350. Oil consumption. From day one and Still. Until I get some of my other projects done it will have to stay that way. At least it will always have fresh oil. Lol

Looking good Fred!! Have fun!


Title: Re: 1989 3CV Streetfighter Project
Post by: Pat Conlon on August 04, 2021, 08:03:04 AM
Lots of burned oil on those pistons…Now would be a perfect time to fix those leaky oil rings or throw those POS Hank Scott pistons away….

Far away….

I noticed that too, Father Pat knows of what he speaks.  Pat, as I recall didn't you have a similar problem with rings that didn't seat?  Now would be the time to address the issue since it's out of the bike and apart.

Yes, it was a hard lesson for me ($$$)
 The tension on the Hank Scott piston oil ring was too light and thus allowing oil to be pulled up into the combustion chamber during closed throttle deceleration.
 A brand new engine burning 1 quart of oil every 800 miles was unacceptable.
 The Hank Scott Pro Lite short skirt pistons might be fine for racing, but they (literally) suck on the street.

My current 83mm Ross pistons work great…..
Dan, Ross makes a 82mm you can use, Fred, Ross makes a 80.5mm piston you can use.
https://andrewsmotorsports.mybigcommerce.com/brands/Ross-Racing-Products.html


Title: Re: 1989 3CV Streetfighter Project
Post by: aviationfred on August 04, 2021, 09:07:08 PM
A bit more progress. Removal of the rear subframe. I never realized how heavy it was. Waiting on the new rear subframe hoop and other parts to continue. Cleaned up the new wheel a bit.



Fred


Title: Re: 1989 3CV Streetfighter Project
Post by: fj1289 on August 04, 2021, 09:41:55 PM
Awesome to see this project going! 

Can’t wait to see your version of a fightered FJ.  Are those cigar boxes you are using for parts organization?!


Title: Re: 1989 3CV Streetfighter Project
Post by: ribbert on August 05, 2021, 04:48:43 AM
My Streetfighter project has officially kicked off. Initially all 3 FJ's will be involved with engine and head swaps.  :scratch_one-s_head:
........
Fred

Great to stuff Fred, an excellent collection of desirable bits to work with and nice to see you in a secure garage with not one, but two lift tables and what appears to be a well kitted out workshop and three FJ builds on the go....FJ heaven! After being dealt a few bad hands in recent times you deserve this.

Unlike restorations, Streetfighter's are a product of the imagination, it'll be interesting to see what yours can come up with.  As you know, Stuart Monk has one on the go as well at the moment.

We've had fighters brought to the forum before but I don't believe we've had a live build, keep the progress reports rolling.

The cam chain caught my eye, why don't you drop it into the case when you remove the cams so it’s out of the way for the duration?

Noel


Title: Re: 1989 3CV Streetfighter Project
Post by: aviationfred on August 05, 2021, 05:49:51 PM
Wiating on engine parts... hopefully they will show up tomorrow..

A small bit of work on the Streetfighter today.. The auxiliary lights came in and mocked up. The Blue Angel Eyes will be tied to the low beam and the White light will be tied to the High Beam.



Fred


Title: Re: 1989 3CV Streetfighter Project
Post by: aviationfred on August 07, 2021, 04:41:56 AM
Today was head swap day. Removal of the oversize valve head that is on the 1995 FJ, too be used on the 1300 engine. Head gaskets and other parts arrived from RPM. The removal was a breeze with no hiccups. The install of the stock head from the stolen bike was just as easy. I absolutely love the YAMAHA timing mark system. TDC with the rotor and get the cam dots lined up with the #3 cam caps and everything is set. Checked valve clearances and only 3 valves needed adjusting.

When the stolen FJ was recovered, the exhaust mid pipe and RPM muffler were missing. I was informed that RPM has a couple of spare mufflers and mid pipes. The new mid pipe and muffler arrived with the head gaskets. I really didn't want to contact Hindle directly for a mid pipe and muffler. I did confirm that the 'Y' pipe can be flipped over and a left side exhaust can be done.  :rofl2:  :yahoo: But this will mean that I will have to buy the head pipes / Y pipe from Hindle and a custom fabricated mid pipe will need to be made by a local muffler shop for the high mount muffler.


Fred


Title: Re: 1989 3CV Streetfighter Project
Post by: aviationfred on August 07, 2021, 04:59:49 AM
The LED headlight bulbs came in for the Streetfighter dual pod light. Photos are of the Halogen low beam and LED low beam. The last photo is with the LED high beam and Auxiliary main lights.


Fred


Title: Re: 1989 3CV Streetfighter Project
Post by: fj1289 on August 07, 2021, 07:49:08 AM
Left side exhaust ... I see what’s happening here!   :good2:


Title: Re: 1989 3CV Streetfighter Project
Post by: Pat Conlon on August 07, 2021, 08:31:50 AM
Left side exhaust ... I see what’s happening here!   :good2:

I’m lost, why Left exhaust?


Title: Re: 1989 3CV Streetfighter Project
Post by: giantkiller on August 07, 2021, 09:58:22 AM
I've got a left side exhaust.  :biggrin:


Title: Re: 1989 3CV Streetfighter Project
Post by: aviationfred on August 07, 2021, 04:56:32 PM
Left side exhaust ... I see what’s happening here!   :good2:

I’m lost, why Left exhaust?


A wheel like this will be installed..... maybe not initially,  but down the road a bit.



Fred


Title: Re: 1989 3CV Streetfighter Project
Post by: aviationfred on August 07, 2021, 08:19:43 PM
Another mock up.... held together with zip ties.

I am going to use a FJ09/Tracer double bubble windscreen as a Bug Screen. Tested the Plasti-Dip to see if masking for stripes would pull the base coat.


Fred


Title: Re: 1989 3CV Streetfighter Project
Post by: giantkiller on August 07, 2021, 08:27:55 PM
I like the double bubble. Fred.  Looks good.


Title: Re: 1989 3CV Streetfighter Project
Post by: fj1289 on August 07, 2021, 10:05:03 PM
Left side exhaust ... I see what’s happening here!   :good2:

I’m lost, why Left exhaust?


A wheel like this will be installed..... maybe not initially,  but down the road a bit.



Fred

Pat must have forgotten about the parts VFR purchased earlier ... with its single sided swing arm


Title: Re: 1989 3CV Streetfighter Project
Post by: aviationfred on August 08, 2021, 01:43:33 AM
The broken engine in Casper has been removed. Started to install the cams in the 1300 engine. There is an issue.... :mad: :ireful: The crankshaft will only rotate about 1/2 a revolution. I will investigate tomorrow.

On a higher note. I rode the 95 home from the garage and it runs great.

Fred


Title: Re: 1989 3CV Streetfighter Project
Post by: Old Rider on August 08, 2021, 05:26:36 AM
Maybe the engine cyl 1 is not set on TDC at the compression stroke  but on the exhaust stroke when installed camchafts ? you can feel when compression stroke is by holding a finger over the plughole


Title: Re: 1989 3CV Streetfighter Project
Post by: Old Rider on August 08, 2021, 09:06:17 AM
Forget my comment above thinking it over it is not possible to check that before cams are installed  :Facepalm:  maybe the camchain has jumped on the crank


Title: Re: 1989 3CV Streetfighter Project
Post by: fj1289 on August 08, 2021, 12:08:02 PM
The broken engine in Casper has been removed. Started to install the cams in the 1300 engine. There is an issue.... :mad: :ireful: The crankshaft will only rotate about 1/2 a revolution. I will investigate tomorrow.

On a higher note. I rode the 95 home from the garage and it runs great.

Fred

Fred - I’ve had this happen a time or two.  Most likely the cam chain has doubled back over itself for a link and is jamming the crankshaft.  Try rocking the crankshaft gently back and forth while pulling out on the cam chain and see if it frees up.  

I typically hang the cam chain on a large breaker bar laying across the the cylinder head.  Although it seems like you could turn the crank shaft with the chain suspended like that - there is still enough slack it will randomly “ball up” on you and lock up the crankshaft. 



Title: Re: 1989 3CV Streetfighter Project
Post by: aviationfred on August 08, 2021, 07:54:49 PM
The broken engine in Casper has been removed. Started to install the cams in the 1300 engine. There is an issue.... :mad: :ireful: The crankshaft will only rotate about 1/2 a revolution. I will investigate tomorrow.

On a higher note. I rode the 95 home from the garage and it runs great.

Fred

Fred - I’ve had this happen a time or two.  Most likely the cam chain has doubled back over itself for a link and is jamming the crankshaft.  Try rocking the crankshaft gently back and forth while pulling out on the cam chain and see if it frees up.  

I typically hang the cam chain on a large breaker bar laying across the the cylinder head.  Although it seems like you could turn the crank shaft with the chain suspended like that - there is still enough slack it will randomly “ball up” on you and lock up the crankshaft. 



I figured out the problem.... with the 1297cc engine, I remembered with the base gasket and head gasket, that one was specific to ther 1297cc kit. I remembered wrong,  :unknown: thinking it was the base gasket. It needs the 80.5mm head gasket. Andrew's Motorsports will be called in the morning for a new 80.5mm head gasket.


Fred


Title: Re: 1989 3CV Streetfighter Project
Post by: giantkiller on August 09, 2021, 03:03:53 PM
Left side exhaust ... I see what’s happening here!   :good2:

I’m lost, why Left exhaust?

My left side exhaust.  :wacko2:


Title: Re: 1989 3CV Streetfighter Project
Post by: aviationfred on August 11, 2021, 06:26:46 PM
More fun with the Plasti-Dip ....  :music:

I am currently on hold due to waiting for parts to be delivered. The fender can be painted, but can not be installed or removed without first removing the front wheel and one fork leg. The spare Carbon Fiber fender comes into play. Normally, I would never consider painting a Carbon Fiber body part. Plasti-Dip is the solution.


Fred


Title: Re: 1989 3CV Streetfighter Project
Post by: giantkiller on August 11, 2021, 11:36:01 PM
Front fender for the 89 was red when I got it. I plasti-dipped it. That was a million year's ago. It's finally getting to where I need to redip it.  Was my first attempt at dipping.


Title: Re: 1989 3CV Streetfighter Project
Post by: aviationfred on August 14, 2021, 05:58:22 PM
Still waiting on the GSX-R1000 upper triple clamp for the Superbike handlebar conversion, and the rear subframe hoop. I did receive the correct head gasket for the 1297cc  engine. Installed the head and cams. I set the timing and will check the valve clearances tomorrow.

I can't wait to get this engine in Casper  :gamer: :yahoo: ..... I should be able to get a months worth of riding in and work out any bugs before the 1000 mile ride to the Vintage Yamaha Rally in September.




Fred


Title: Re: 1989 3CV Streetfighter Project
Post by: aviationfred on August 17, 2021, 02:26:01 AM
Made some headway today. I got the needed valve shims from Sean Morley of Morley's Muscle. The Vmax version of Randy and RPM. While there, I was introduced to his welder. We brought the broken engine with us. All of 10 minutes was that it took to weld a repair. Got back to the garage to finish. Drilled, tapped and filed the repair. The engine will now be put aside and wait until the Streetfighter frame gets powder coated.



Fred


Title: Re: 1989 3CV Streetfighter Project
Post by: Carson City Paul on August 17, 2021, 09:03:54 AM
Made some headway today. I got the needed valve shims from Sean Morley of Morley's Muscle. The Vmax version of Randy and RPM. While there, I was introduced to his welder. We brought the broken engine with us. All of 10 minutes was that it took to weld a repair. Got back to the garage to finish. Drilled, tapped and filed the repair. The engine will now be put aside and wait until the Streetfighter frame gets powder coated.



Fred

There is one thing you need to know. Welded aluminum is not as strong as it was in original form, so your torque will be less with that bolt.


Title: Re: 1989 3CV Streetfighter Project
Post by: aviationfred on August 17, 2021, 06:05:51 PM
Not perfectly adjusted yet.... but here is the rear fender and tag holder for the Streetfighter. A license plate frame with a built in LED strip for the tag light is on it's way.


Title: Re: 1989 3CV Streetfighter Project
Post by: aviationfred on August 22, 2021, 10:57:22 PM
And Casper is alive with the transplanted 1297cc engine and the oversize valve head donated by the 95 FJ.  :yahoo: :good2: :gamer:

Start up video

https://youtu.be/JaICfwQdNFw



Fred


Title: Re: 1989 3CV Streetfighter Project
Post by: aviationfred on August 23, 2021, 05:05:08 AM
Casper is completely back together. Now the focus can be on the Streetfighter.

Video with a 5th gear roll on...60mph to about 110mph
https://youtu.be/bHAx7q5G2bQ


Fred


Title: Re: 1989 3CV Streetfighter Project
Post by: aviationfred on August 23, 2021, 04:03:55 PM
Working on graphics for the Streetfighter with Jeff Shaw.




Fred


Title: Re: 1989 3CV Streetfighter Project
Post by: fj1289 on August 23, 2021, 04:24:46 PM
I’ve always liked the “AHAMAY” decals lol

Maybe SFJ1200?





Title: Re: 1989 3CV Streetfighter Project
Post by: aviationfred on August 24, 2021, 07:31:25 PM
The graphics are done and shipped.



Fred


Title: Re: 1989 3CV Streetfighter Project
Post by: aviationfred on August 25, 2021, 09:51:19 PM
Received the tag frame with LED tag lights integrated. I went to the tag office and turned all the paperwork in for a new Title and registration. Went with a personalized tag. The total fees were $120.00.
The Billet upper triple clamp needed a bit of trimming to mount the FZ750 ignition switch. The 1st frame item to be cut off is the OEM shock adjustment support. The fuel tank is on for general ideas on where the new subframe will be welded on and where bends will need to be.




Fred


Title: Re: 1989 3CV Streetfighter Project
Post by: aviationfred on August 27, 2021, 02:40:34 AM
Using my Airhawk as a seat template.... a rough idea on the seat positioning and the rough cut tail cowling.



Fred


Title: Re: 1989 3CV Streetfighter Project
Post by: GhostMerc on September 30, 2021, 04:55:27 AM
Looking good!

This build is relevant to my interests.  I bought an FJ09 earlier this year and my FJ1200 is wrapped in plastic at the moment.  When I have time I'm going to rebuild the old bike into a streetfighter myself.  Call it an MT-13 and try to use a similar paint scheme as an MT-10.


Title: Re: 1989 3CV Streetfighter Project
Post by: aviationfred on October 11, 2021, 11:27:34 PM
I have not posted any progress in awhile.
Today I fabricated a frame for the Bug Screen. I have it tack welded in place and mounted the Bug Screen. I used a FJ-09 Double Bubble windscreen. This gives me the option to try some different sizes and shapes.

Next up will be fabricating the rear subframe and gas tank mount.



Fred


Title: Re: 1989 3CV Streetfighter Project
Post by: aviationfred on November 03, 2021, 08:05:03 PM
Working on getting the sub-frame sorted to be welded.

The Tail light, Brake light and turn signals are mounted in the sub-frame.




Fred


Title: Re: 1989 3CV Streetfighter Project
Post by: andyoutandabout on November 03, 2021, 08:12:40 PM
Delicious wheel color