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Brake Upgrade for My FJ1100

Started by krusty, June 13, 2020, 08:34:16 PM

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krusty

Quote from: T Legg on June 26, 2020, 02:01:13 AM
The kickstand has to be up also when it is in gear to start.
I have 3 1100s and none have a kickstand switch.
91 FJ1200
84 FJ1100 x 2
85 FJ1100
89 GL1500
76 CB750F1
72 CB350F
63 C92 x 2
59 C76
62 C100
63 C100
60 Colleda 250TA x 3
63 Suzuki MD50
77 DT125E
77 DT175E x 2
79 DT250F

T Legg

Quote from: krusty on June 26, 2020, 04:33:03 AM
Quote from: T Legg on June 26, 2020, 02:01:13 AM
The kickstand has to be up also when it is in gear to start.
I have 3 1100s and none have a kickstand switch.
I have two fj1100's and they both have kickstand switch's along with kickstand switch relay's. Maybe it is an American model verses Australian model thing.
T Legg

krusty

Quote from: krusty on June 26, 2020, 04:33:03 AM
Quote from: T Legg on June 26, 2020, 02:01:13 AM
The kickstand has to be up also when it is in gear to start.
I have 3 1100s and none have a kickstand switch.

I've checked my Haynes shop manual wiring diagrams and found that the UK version 36Y has no side stand switch. My bikes are 50K. I am guessing the clutch switch is somehow tied to the neutral light being on or off. Any ideas?
91 FJ1200
84 FJ1100 x 2
85 FJ1100
89 GL1500
76 CB750F1
72 CB350F
63 C92 x 2
59 C76
62 C100
63 C100
60 Colleda 250TA x 3
63 Suzuki MD50
77 DT125E
77 DT175E x 2
79 DT250F

T Legg

I looked at the UK diagram in my clymer manual . If the Haynes manual is like the clymer it doesn't have the schematic of the relays. I made a crude drawing of the starter circuit. The starter cut off relay magnetic coil is connected to positive through the key switch and then through the kill switch. the other side of the starter cut off relay magnetic coil is connected to the clutch switch by the black /yellow wire to the clutch switch .when the clutch is pulled the  coil is connected to ground and energized closing the relay contacts.now if the starter switch is pushed it will turn over. The black/yellow wire is also connected through the diode block to the neutral switch which  when closed will also connect the starter cutoff relay to ground and energized the magnetic coil. If it is starting in neutral then the starter cutoff relay is working so the problem must be in the black /yellow  wire connection between the clutch switch and the starter cutoff relay ,the clutch switch or the black wire connection between the clutch switch and ground. Good Luck I hope this helps
T Legg

krusty

Thank you for for that. I'll try and digest it all over the next few days.
Now waiting for blue spot seals to arrive but now have noticed a fork seal is leaking a little so its the old 'one thing leads to another', again. The bike has 88 forks and I have a spare set of Icon progressive springs that I'll try out in it. These came out of my 91 1200 and were replaced by RPM springs and valves. Anyone see any potential compatibility problem with that? The most obvious to me, without looking, would be spring length.
91 FJ1200
84 FJ1100 x 2
85 FJ1100
89 GL1500
76 CB750F1
72 CB350F
63 C92 x 2
59 C76
62 C100
63 C100
60 Colleda 250TA x 3
63 Suzuki MD50
77 DT125E
77 DT175E x 2
79 DT250F

Millietant

Quote from: krusty on June 28, 2020, 09:30:26 PM
Quote from: krusty on June 26, 2020, 04:33:03 AM
Quote from: T Legg on June 26, 2020, 02:01:13 AM
The kickstand has to be up also when it is in gear to start.
I have 3 1100s and none have a kickstand switch.

I've checked my Haynes shop manual wiring diagrams and found that the UK version 36Y has no side stand switch. My bikes are 50K. I am guessing the clutch switch is somehow tied to the neutral light being on or off. Any ideas?

That's strange Krusty, our UK FJ's do have side stand cut off switches. Never noticed that they aren't shown in my Haynes manual !
Dean

'89 FJ 1200 3CV - owned from new.
'89 FJ 1200 3CV - no engine, tank, seat....parts bike for the future.
'88 FJ 1200 3CV - complete runner 2024 resto project
'88 FJ 1200 3CV - became a race bike, no longer with us.
'86 FJ 1200 1TX - sold to my boss to finance the '89 3CV I still own.

Sparky84

Quote from: T Legg on June 29, 2020, 02:24:46 AM
I looked at the UK diagram in my clymer manual . If the Haynes manual is like the clymer it doesn't have the schematic of the relays. I made a crude drawing of the starter circuit. The starter cut off relay magnetic coil is connected to positive through the key switch and then through the kill switch. the other side of the starter cut off relay magnetic coil is connected to the clutch switch by the black /yellow wire to the clutch switch .when the clutch is pulled the  coil is connected to ground and energized closing the relay contacts.now if the starter switch is pushed it will turn over. The black/yellow wire is also connected through the diode block to the neutral switch which  when closed will also connect the starter cutoff relay to ground and energized the magnetic coil. If it is starting in neutral then the starter cutoff relay is working so the problem must be in the black /yellow  wire connection between the clutch switch and the starter cutoff relay ,the clutch switch or the black wire connection between the clutch switch and ground. Good Luck I hope this helps
Sorry about rotation.

http://fjowners.com/gallery/11/4753_02_07_20_2_07_53.jpeg


1984 FJ1100
1979 Kawasaki Z1300
1972 Honda CB750/4 K2

T Legg

That looks official. I'm glad my drawing matches it. I had to extrapolate the wiring by matching the clymer UK diagram with no relay diagrams to the factory manual for my US fj1100 with relay diagrams but with the extra kickstand switch and relay.
T Legg

krusty

An update on the brake caliper swap. All fitted and working good. No problems fitting new seals etc. I bled the brakes the normal way but still ended up with a "soft" lever. It was late in the day so I decided to do the old lever in overnight trick if you know what I mean. What I did was pull the lever in about 3/4 and held it there by wrapping some masking tape around the lever and the grip to hold the lever in that position. Next morning I removed the tape to release the lever and all was good. Took it for a test ride and everything is working as it should.

At the moment I have the rear suspension removed from a parts donor 1100. I'll rebuild it then fit it to my rider 1100. In the process of cleaning the swing arm. Question; what kind of finish does the ally swingarm have?
91 FJ1200
84 FJ1100 x 2
85 FJ1100
89 GL1500
76 CB750F1
72 CB350F
63 C92 x 2
59 C76
62 C100
63 C100
60 Colleda 250TA x 3
63 Suzuki MD50
77 DT125E
77 DT175E x 2
79 DT250F

FJmonkey

Clear anodize. Like Mil-8625 type II
The glass is not half full, it was engineered with a 2X safety factor.

'86 Ambulance - Bent frame, cracked case, due for an overhaul
'89 Stormy Blue - Suits my Dark Side

krusty

Quote from: FJmonkey on July 21, 2020, 12:52:03 AM
Clear anodize. Like Mil-8625 type II
Thanks. That confirms what I thought. What's the common (cheap?) method to have it looking looking good again?
91 FJ1200
84 FJ1100 x 2
85 FJ1100
89 GL1500
76 CB750F1
72 CB350F
63 C92 x 2
59 C76
62 C100
63 C100
60 Colleda 250TA x 3
63 Suzuki MD50
77 DT125E
77 DT175E x 2
79 DT250F