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Repair of the Christmas roasted FJ

Started by aviationfred, January 07, 2019, 11:41:17 PM

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T Legg

I've been using a blow dryer to soften up my intake boots before installing my carbs.It works well with old stiff boots.
T Legg

Tuned forks

Fred, you   bought   NEW   carburetors?  The old ones were not rebuildable?  They sure look pretty.

Joe
1990 FJ1200-the reacher
1990 FZR 1000-crotch rocket

aviationfred

Quote from: Tuned forks on January 31, 2019, 10:10:20 PM
you   bought   NEW   carburetors?  The old ones were not rebuildable? 

Joe


Yes, I bought brand new carbs. The pre tuned by RPM versions. The old carbs were damaged beyond repair. A combination of, the Fire and Previous owners ham fisted attacks (maintenance) on the carbs

From the very first tank of fuel when I purchased this bike, I noticed fuel consumption was bad, and much more than even my FJ1300. A few other small things were noticed over the year of ownership that had me questioning the operation of the carbs. Randy confirmed this when he disassembled the carbs.

Fred
I'm not the fastest FJ rider, I am 'half-fast', the fastest slow guy....

Current
2008 VFR800 RC46 Vtec
1996 VFR750 RC36/2
1990 FJ1300 (1297cc) Casper
1990 VFR750 RC36/1 Minnie
1989 FJ1200 Lazarus, the Streetfighter Project
1985 VF500F RC31 Interceptor

RPM - Robert

I wouldn't say "beyond" repair, but the cost of parts to repair them properly would have been almost equivalent to a new set. If new sets were no longer available. In all likelihood these burned up ones could have been repaired with no problems, along with the problems from previous maintenance. Looks like Fred will be back on the road in no time now.  :good2:

Pat Conlon

Fred, did you put fresh valve bolt cover grommets in? I wonder if the old ones hardened with the heat.

Fine job laddie! You'll be riding this weekend :good:
1) Free Owners Manual download: https://tinyurl.com/fmsz7hk9
2) Don't store your FJ with E10 fuel https://tinyurl.com/3cjrfct5
3) Replace your old stock rubber brake lines.
4) Important items for the '84-87 FJ's:
Safety wire: https://tinyurl.com/99zp8ufh
Fuel line: https://tinyurl.com/bdff9bf3

aviationfred

Quote from: Pat Conlon on February 01, 2019, 10:53:13 AM
Fred, did you put fresh valve bolt cover grommets in? I wonder if the old ones hardened with the heat.

Fine job laddie! You'll be riding this weekend :good:


They don't appear to have any damage. I will monitor them for leaks after I get the bike up and running.

Fred
I'm not the fastest FJ rider, I am 'half-fast', the fastest slow guy....

Current
2008 VFR800 RC46 Vtec
1996 VFR750 RC36/2
1990 FJ1300 (1297cc) Casper
1990 VFR750 RC36/1 Minnie
1989 FJ1200 Lazarus, the Streetfighter Project
1985 VF500F RC31 Interceptor

aviationfred

The ignition switch connector got a bit melted so it needs changed. The New throttle cables have been installed and everything has been tidyed up. I did get a new fuel line from O'Reilly's. New petcock and fuel filter installed.

Fred
I'm not the fastest FJ rider, I am 'half-fast', the fastest slow guy....

Current
2008 VFR800 RC46 Vtec
1996 VFR750 RC36/2
1990 FJ1300 (1297cc) Casper
1990 VFR750 RC36/1 Minnie
1989 FJ1200 Lazarus, the Streetfighter Project
1985 VF500F RC31 Interceptor

aviationfred

All ready to put fuel in the tank and check for leaks. Primed the carbs and no leaks.  :dance2: the bike fired up with some coaxing of added throttle. The idle adjustment was way way low. Made the appropriate adjustment and I have a running FJ again.  :yahoo:  :music:


Hopefully the video will post.

https://youtu.be/lUPPEr5UBbE

Fred
I'm not the fastest FJ rider, I am 'half-fast', the fastest slow guy....

Current
2008 VFR800 RC46 Vtec
1996 VFR750 RC36/2
1990 FJ1300 (1297cc) Casper
1990 VFR750 RC36/1 Minnie
1989 FJ1200 Lazarus, the Streetfighter Project
1985 VF500F RC31 Interceptor

Tuned forks

Fred, because of your work experience, do you use electrical connectors that are aviation rated?  I wonder if you don't like the 3M Weatherpack connectors?

Joe
1990 FJ1200-the reacher
1990 FZR 1000-crotch rocket

ZOA NOM

This is turning out to be a hell of a good save, Fred.
Rick

Current:
2010 Honda VFR1200 DCT (Full Auto!)
1993 FJ/GSXR 1200 (-ABS)
1987 Porsche 911 Carrera (Race)
1988 Porsche Carrera (Street)
Previous:
1993 FJ1200 (FIREBALL)
1993 FJ1200ABS (RIP my collar bone)
1986 FZ750
1984 FJ600
1982 Seca

Firehawk068

Alan H.
Denver, CO
'90 FJ1200

aviationfred

Quote from: Tuned forks on February 01, 2019, 09:43:28 PM
Fred, because of your work experience, do you use electrical connectors that are aviation rated?  I wonder if you don't like the 3M Weatherpack connectors?

Joe


I have tried using some actual aircraft connectors and splices. The connectors that are weather proof typical are metal and fairly bulky. The splices have a drawback as they are designed for use with Teflon insulated wires. The insulation is very thin walled and have a very high heat resistance. The problem with motorcycle wires is... The insulation is thicker and not heat resistant at all. To use the environmental splices, the heat shrinkable sleeve barely fits over the insulation and the FJ wires have a tendency to melt and/or char trying to get the sleeves to shrink properly.

I have had great success with the Molex style connectors. They are not much different from most of the FJ connectors.


Fred
I'm not the fastest FJ rider, I am 'half-fast', the fastest slow guy....

Current
2008 VFR800 RC46 Vtec
1996 VFR750 RC36/2
1990 FJ1300 (1297cc) Casper
1990 VFR750 RC36/1 Minnie
1989 FJ1200 Lazarus, the Streetfighter Project
1985 VF500F RC31 Interceptor

Troyskie

Nice work on the repairs Fred.

Troyskie
1984 FJ1100 Ms Effie brand new :)
1984 FJ1100 Pearlie, stock as.
1985 FJ1100 Mr Effie 647,000K and still running hard.
1985 FJ1200 'Yummy' takes a licking & keeps on ticking
After all is said and done, more is said than done :)
2013 Trumpy Tiger 800, let's do a lap of Oz

aviationfred

A late post..... I got about 100 miles on the bike Sunday and it performed flawlessly. Can't wait for Rally season. Bring on the WCR.

Fred
I'm not the fastest FJ rider, I am 'half-fast', the fastest slow guy....

Current
2008 VFR800 RC46 Vtec
1996 VFR750 RC36/2
1990 FJ1300 (1297cc) Casper
1990 VFR750 RC36/1 Minnie
1989 FJ1200 Lazarus, the Streetfighter Project
1985 VF500F RC31 Interceptor

andyoutandabout

Hence forth this shall be the standard by which teal stripers are judged.
Nailed it on the rebuild.
Nice one Fred.
life without a bike is just life