DO THE TON

Blood Sweat Tears and Grease => Projects => Restorations => Topic started by: Kickeroo on Jul 28, 2011, 18:42:21

Title: 1984 Yamaha FJ 600- Rise of "The Mighty Jig"
Post by: Kickeroo on Jul 28, 2011, 18:42:21
What a day....retained a divorce lawyer, and brought home all of my extraneous junk.

Brought her home Wednesday, July 27th, my 25th Birthday present, the 1984 Yamaha FJ600, the one that started it all for me.  The ebay watch list of stuff it will need is growing exponentially, as are the bikebandit list, the dennis kirk lise, etc, etc:

TO DO LIST AS OF 09/25/2013;
From here, and I guess it's as good a time as any to start a to-do list:
1. Clean up and install donor carbs with pod filters (they didn't fit, so I sold them!
2. Finish electrics with coils, new relays, and new fuses where appliciable
3. Figure out what to do about clutch.
4. Media blast exhaust parts, paint with hi-temp black paint, reinstall
5. Re-install cleaned tank.  Put some fresh gas in
6. What the hell, see if she'll start Nope.
7. Change oil in forks, change seals.
8. remove old front tire, clean rim as best as can be, replace bearings, replace tire.
9. replace front brake pads, REPLACE all tubes in system.  Replace fluid and bleed (need help)
10. Replace stearing bearings while we're here.
11. Do something about the seat. Re-cover ($) or replace ($$)
12. Remove rear wheel, remove old tire, clean rim as best as can be replace bearings. Inspect/replace rear sprocket  :o  replace tire
13. Replace chain.
14. Inspect/replace front sprocket.
15. inspect entire swing-arm assembly.  clean, inspect/replace necessary bits.
16. Do something about the yellow patina on aluminum parts (new 2/2/12)
17. Now that it's running (and it is as of 9/20/13), synch carbs, find source of vacuum leack
18. Align rear wheel like an actual bike builder
19. Strengthen new-to-me fairing so that it doesn't break
20. Find source of auxiliary lighting failures (turn signals, horn, neutral light)
20a. pray it isn't the flasher relay
21. Find aftermarket mirrors
22. Go to bike junkyard and find nuts and bolts needed for exhaust manifold, battery box, turn signals
22. Ride past ex's house, middle finger extended.

More as I think of it.


What it would have looked at when it was new:
(http://www.motorcyclespecs.co.za/Gallery%20%20A/Yamaha%20FJ600%2084%20%202.jpg)
Stuff that's impossible to find (to be added to):
The chin fairing
Side covers that haven't been roached
Almost impossibe:
Good tires
Minor Inconveinience:
PA Title long since missing, but only $35 away
First....yes, I'm guilty of negligence
(http://i35.photobucket.com/albums/d151/Kickeroo/Rise%20of%20the%20FJ600/thefj001.jpg)
Umbrella removed:
(http://i35.photobucket.com/albums/d151/Kickeroo/Rise%20of%20the%20FJ600/thefj002.jpg)
And only 30,992 miles!
(http://i35.photobucket.com/albums/d151/Kickeroo/Rise%20of%20the%20FJ600/thefj003.jpg)
It really only gets worse from here:
(http://i35.photobucket.com/albums/d151/Kickeroo/Rise%20of%20the%20FJ600/thefj004.jpg)
Windsheild is a goner...knew that
(http://i35.photobucket.com/albums/d151/Kickeroo/Rise%20of%20the%20FJ600/thefj005.jpg)
Sidecovers are pretty ratted out
(http://i35.photobucket.com/albums/d151/Kickeroo/Rise%20of%20the%20FJ600/thefj006.jpg)
New flo-thru vision!
(http://i35.photobucket.com/albums/d151/Kickeroo/Rise%20of%20the%20FJ600/thefj007.jpg)
fork seals are.....good??? really?
(http://i35.photobucket.com/albums/d151/Kickeroo/Rise%20of%20the%20FJ600/thefj008.jpg)
Last shot in the old 'hood
(http://i35.photobucket.com/albums/d151/Kickeroo/Rise%20of%20the%20FJ600/thefj009.jpg)
Parked in 96..
(http://i35.photobucket.com/albums/d151/Kickeroo/Rise%20of%20the%20FJ600/thefj010.jpg)
It was June....i was broke
(http://i35.photobucket.com/albums/d151/Kickeroo/Rise%20of%20the%20FJ600/thefj011.jpg)
Again, look at the clean section
(http://i35.photobucket.com/albums/d151/Kickeroo/Rise%20of%20the%20FJ600/thefj012.jpg)
All tied down on the trailer that brought it here 11 years ago
(http://i35.photobucket.com/albums/d151/Kickeroo/Rise%20of%20the%20FJ600/thefj013.jpg)
I know for a fact that chain is kinked
(http://i35.photobucket.com/albums/d151/Kickeroo/Rise%20of%20the%20FJ600/thefj014.jpg)
Look closely, and you can see where mice were living in the tail section
(http://i35.photobucket.com/albums/d151/Kickeroo/Rise%20of%20the%20FJ600/thefj015.jpg)
Pod filters gave up the ghost a while ago
(http://i35.photobucket.com/albums/d151/Kickeroo/Rise%20of%20the%20FJ600/thefj016.jpg)
Thought bubble from the Guzzi, "No, no, no...dona bring dat in here"
(http://i35.photobucket.com/albums/d151/Kickeroo/Rise%20of%20the%20FJ600/thefj017.jpg)
Do i own ANYTHING that doesn't have a patina to it??  really?
(http://i35.photobucket.com/albums/d151/Kickeroo/Rise%20of%20the%20FJ600/thefj018.jpg)
Hey, look! a stoppie!
(http://i35.photobucket.com/albums/d151/Kickeroo/Rise%20of%20the%20FJ600/thefj019.jpg)
Summary
No illusions of grandeur here.  The old girl deserves better than what I can do, but she's one loyal tough old broad
Title: Re: 1984 Yamaha FJ 600- Rise of "The Mighty Jig"
Post by: jimmer on Jul 28, 2011, 19:13:26
Man, have you got your work cut out for you!!  These are cool bikes.I bought one shortly after watching these bikes kick butt at the 24 hours of Nelson Ledges in '84.When I bought mine it had a mouse living by the airbox,must be an FJ thing.Funny part is,he didn't come out until after  the high speed test ride!Had mine for a couple years and haven't seen a nice one since.I'll have to send you a couple of pics. Enjoy it!
Title: Re: 1984 Yamaha FJ 600- Rise of "The Mighty Jig"
Post by: Kickeroo on Jul 29, 2011, 08:33:56
I HAVE enjoyed it...since March of 1992! That's why it's in this sorry state. But I do welcome any and all stories, advice, and free parts ;)
Took off the seat, and realized I was not alone.  Well, I thought I wasn't alone. A couple of well-gloved handfuls of old foam rubber (from what, I have no idea), 60 seconds of shop-vac, some Simple Green, and a disinfectant wipe later, the space is now empty, and I guess, open for new occupants...uh, NOT!
(http://i35.photobucket.com/albums/d151/Kickeroo/Rise%20of%20the%20FJ600/thefj027.jpg)
Title: Re: 1984 Yamaha FJ 600- Rise of "The Mighty Jig"
Post by: JustinLonghorn on Jul 29, 2011, 08:54:02
The Pod filters might have given up the ghost, but the FJ still has life in her. Don't junkyard that bike, please. I am sure that she will roar to life again soon.
 
If you are going to junk it, let me know first.
 
Good luck man, she could be one hell of a scoot again.
Title: Re: 1984 Yamaha FJ 600- Rise of "The Mighty Jig"
Post by: Kickeroo on Jul 29, 2011, 09:45:18
Since I'm a few hours away from scoring a big-ticket fix-me-up part, I don't think it'd be in my best interest to junk her.  I can't say with a straight face that the project will be done in 8 weeks, but as time, energy, and money become available, I'll get her back in action. No worries.
Title: Re: 1984 Yamaha FJ 600- Rise of "The Mighty Jig"
Post by: Griff5268 on Jul 29, 2011, 10:54:24
My Radian took so many parts from that model. You may want to look into Phazer, and Radian parts as most of these parts will fit your bike. The FJ, FZ, YX (Radian), and Phazer are almost he same bike plus minus fairings.. Hope this helps.
Title: Re: 1984 Yamaha FJ 600- Rise of "The Mighty Jig"
Post by: Kickeroo on Jul 29, 2011, 16:59:51
first...like I said...no more meeses
(http://i35.photobucket.com/albums/d151/Kickeroo/Rise%20of%20the%20FJ600/tankandframe003.jpg)
draining the last of the root-beer-brown 16 year old gas
(http://i35.photobucket.com/albums/d151/Kickeroo/Rise%20of%20the%20FJ600/tankandframe001.jpg)
State of the frame.  Looks good
(http://i35.photobucket.com/albums/d151/Kickeroo/Rise%20of%20the%20FJ600/tankandframe002.jpg)
The FJ's dirty little BITD ignition secret....
(http://i35.photobucket.com/albums/d151/Kickeroo/Rise%20of%20the%20FJ600/tankandframe004.jpg)
Just then, an old pod filter made a break for it:
(http://i35.photobucket.com/albums/d151/Kickeroo/Rise%20of%20the%20FJ600/tankandframe005.jpg)
Title: Re: 1984 Yamaha FJ 600- Rise of "The Mighty Jig"
Post by: Kickeroo on Jul 30, 2011, 17:58:21
5PM, EST, 7/30/11....derusting the tank using electolosys has begun.  No pictures to report, unless it works like gangbusters.
 
oh, what the heck:
My science project:
First, what it looks like inside the gas tank:
(http://i35.photobucket.com/albums/d151/Kickeroo/Rise%20of%20the%20FJ600/Tankde-rusting002.jpg)
In order to insure continuity of an electric charge, I had to scrape away a little paint:
(http://i35.photobucket.com/albums/d151/Kickeroo/Rise%20of%20the%20FJ600/Tankde-rusting004.jpg)
This, as a weak solution, forms a nice electolyte, since it's mostly sodium carbonate
(http://i35.photobucket.com/albums/d151/Kickeroo/Rise%20of%20the%20FJ600/Tankde-rusting007.jpg)
The nuts and washers form a donor of electrons to the rust spots on the tank walls, turning the rust into ferrous ferric (black) oxide. really
(http://i35.photobucket.com/albums/d151/Kickeroo/Rise%20of%20the%20FJ600/Tankde-rusting006.jpg)
Positive lead goes to the bolt.  Negative lead to the scraped-away section of the tank.  Plug it in, and walk away.  To be fair, this is the first go-around.  I hadn't fully sealed the outlets to the petcock (removed for disassembly and cleaning) and the whole thinng promptly leaked. I re-installed the petcock, and moved the the she-bang into the garage.  As of this writing 12:00 EST 7-31-11, it's still chugging away at it.
(http://i35.photobucket.com/albums/d151/Kickeroo/Rise%20of%20the%20FJ600/Tankde-rusting008.jpg)
If it doesn't work, I have the other methods at the ready, including "the Works" toilet cleaner and the ability to shake the tank with some gas and a few loose nuts and bolts in it.
Stay tuned
 
 
Title: Re: 1984 Yamaha FJ 600- Rise of "The Mighty Jig"
Post by: Kickeroo on Aug 02, 2011, 08:34:53
still working on it:
(http://i35.photobucket.com/albums/d151/Kickeroo/Rise%20of%20the%20FJ600/rustpart2work001.jpg)
Occasionally, I change out the cluster of sacrificial nuts and washers:
(http://i35.photobucket.com/albums/d151/Kickeroo/Rise%20of%20the%20FJ600/rustpart2work003.jpg)
Title: Re: 1984 Yamaha FJ 600- Rise of "The Mighty Jig"
Post by: Griff5268 on Aug 02, 2011, 14:28:03
Looking good..Keep chuggin man.
Title: Re: 1984 Yamaha FJ 600- Rise of "The Mighty Jig"
Post by: VonYinzer on Aug 02, 2011, 14:33:20
Very cool. Looking forward to seeing her come to life!
Title: Re: 1984 Yamaha FJ 600- Rise of "The Mighty Jig"
Post by: Kickeroo on Aug 06, 2011, 10:50:29
Shopping for basics in two days: battery, filter, oil, etc.  A local friend is GIVING me a set of clean '87 FZ600 carbs to swap out, if only so I can get her running sooner than later. I seem to remember the FJ's having a Barnett kit installed in them, so I'm not getting rid of them.  We'l see.  Obviousy, with a swap out, some adjustments will need to be made. Duh.  I'm just updating what I know.
Title: Re: 1984 Yamaha FJ 600- Rise of "The Mighty Jig"
Post by: Kickeroo on Aug 12, 2011, 12:18:26
Ok, I'm poking at the FJ as much as I can, with funds, time and energy being my nemesis.
 
First the good news: Changed out the oil and filter:
(http://i35.photobucket.com/albums/d151/Kickeroo/Rise%20of%20the%20FJ600/FJoilchange001.jpg)
Bad news...had to take my way-trick-back-in-the-day Vance and Hines exhaust off:
(http://i35.photobucket.com/albums/d151/Kickeroo/Rise%20of%20the%20FJ600/FJoilchange002.jpg)
The metal is intact, just shitty looking with all of the rust.  I'll have to table that idea for a bit:
(http://i35.photobucket.com/albums/d151/Kickeroo/Rise%20of%20the%20FJ600/FJoilchange003.jpg)
Donor FZ600 carbs GIVEN to me, that were clean as of a year ago:
(http://i35.photobucket.com/albums/d151/Kickeroo/Rise%20of%20the%20FJ600/FJoilchange004.jpg)
Versus my original ones that may or may not have a jet kit in them:
(http://i35.photobucket.com/albums/d151/Kickeroo/Rise%20of%20the%20FJ600/FJoilchange005.jpg)
Question: what's the best way to remove bar-ends without unsightly vice-grip tool marks?
(http://i35.photobucket.com/albums/d151/Kickeroo/Rise%20of%20the%20FJ600/FJoilchange006.jpg)
Not that I'm crazy about the bar set-up to begin with.
(http://i35.photobucket.com/albums/d151/Kickeroo/Rise%20of%20the%20FJ600/FJoilchange007.jpg)
The surface corrosion beneath the throttle is part of the reason I'd like to get the bar-ends off
(http://i35.photobucket.com/albums/d151/Kickeroo/Rise%20of%20the%20FJ600/FJoilchange008.jpg)
And in the cart-before-the-horse department: a new battery.  Charged it up, put it in, and just to see if the wiring was as intact as I remember, I turned the key.......and nothing. The wiring diagram doesn't appear to have a break in the whole of the system if the headlight or gas tank are removed, but then again, I haven't had a chance to go all OCD on the subject yet.  Any ideas anyone?
(http://i35.photobucket.com/albums/d151/Kickeroo/Rise%20of%20the%20FJ600/FJoilchange009.jpg)
 
Thanks for looking!
Title: Re: 1984 Yamaha FJ 600- Rise of "The Mighty Jig"
Post by: Kickeroo on Aug 17, 2011, 10:47:27
From an electrical standpoint, I've determined that the starter relay and the sidestand relay are "out of spec" and new ones have been independantly ordered. Thankfully, the really expensive one, the flasher relay, is still good.  I have yet to even attempt to see if she'll fire up, since I haven't swapped out the carbs yet.  I'm merely cleaning everything as I go along, just so I can have it running as I remember it by a very symbolic Decemeber 14th. I did receive a replacement fairing that I bought online.  Now, nothing is perfect, and it's far and away in better condition that the one I had.  However, it's not without its issues, and some of the ABS needs to be reinforced at the fairing-stay connections, and at one of the two headlight trim retainer fittings.  I'm told Duramix has a number of products that will help this....so I'll be ordering a few things later next week.  That's the update for now.
Title: Re: 1984 Yamaha FJ 600- Rise of "The Mighty Jig"
Post by: Kickeroo on Aug 18, 2011, 08:39:46
Soda-blasting this weekend: just this; Hi temp-rattle can to follow
(http://i35.photobucket.com/albums/d151/Kickeroo/Rise%20of%20the%20FJ600/FJoilchange003.jpg)
Title: Re: 1984 Yamaha FJ 600- Rise of "The Mighty Jig"
Post by: Kickeroo on Aug 19, 2011, 09:38:49
See:
http://www.dotheton.com/forum/index.php?topic=28698.0 (http://www.dotheton.com/forum/index.php?topic=28698.0)
Title: Re: 1984 Yamaha FJ 600- Rise of "The Mighty Jig"
Post by: Kickeroo on Aug 19, 2011, 11:10:35
....and success! The Vance and Hines exhaust is ready for blasting.
Title: Re: 1984 Yamaha FJ 600- Rise of "The Mighty Jig"
Post by: Kickeroo on Aug 20, 2011, 09:45:04
As promised.  The now-separated V&H exhaust.....and the bonus was shaking out the remnants of whatever was living in there
(http://i35.photobucket.com/albums/d151/Kickeroo/Rise%20of%20the%20FJ600/parts001.jpg)
Next up is cleaning up this area.  Dig the custom aluminum bracket that, I'm guessing the P.O. (pre-1992) had made, or made him/herself.
(http://i35.photobucket.com/albums/d151/Kickeroo/Rise%20of%20the%20FJ600/parts002.jpg)
...and I'm cleaning up all of the coil stuff, mainly because I can rationalize parting with another $150 just to replace them. 
(http://i35.photobucket.com/albums/d151/Kickeroo/Rise%20of%20the%20FJ600/parts003.jpg)
All of the brackets have spent the night in a environmentally friendly solution of lemon-juice and baking soda.  Not a fabulous result, but perhaps a rattle can job to make them look as though I give a crap.  More to that later.

do to list moved to page 1
Title: Re: 1984 Yamaha FJ 600- Rise of "The Mighty Jig"
Post by: Kickeroo on Aug 23, 2011, 17:58:24
After shots of the V&H exhaust when a buddy sandblasted them:
yes, I suck at metal polishing
(http://i35.photobucket.com/albums/d151/Kickeroo/Rise%20of%20the%20FJ600/sandblast005.jpg)
The header.
(http://i35.photobucket.com/albums/d151/Kickeroo/Rise%20of%20the%20FJ600/sandblast008.jpg)
In other news:
Coils all cleaned, and the relays have been installed.  The entire electrical system is now functional, including brake lights, horn, turn signals and the biggie: the starter.
I replaced the decrepit NGK's for E3 3.36, and for giggles, I pushed the starter button, if only to circulate some oil. SHE CRANKS!!!!
Because I'm an idiot, I'll have to drain the Fully Synthetic 10W30 soon, because I have new cluitch plates to install.  I know this, well, because you can pull the clutch lever, and yes, I checked, the cable is fine. 
My rattle-can paint job on the exhaust is next.  It won't be pretty, but it'll look better than what I had.
Title: Re: 1984 Yamaha FJ 600- Rise of "The Mighty Jig"
Post by: Kickeroo on Aug 25, 2011, 06:57:47
Clutch plates are in, and a new cable is on order, because it just makes good sense.  This'll give me something to do while Hurrican Irene hits Central Virginia.
Title: Re: 1984 Yamaha FJ 600- Rise of "The Mighty Jig"
Post by: scott s on Aug 25, 2011, 19:56:06
 Don't give up on the ol' girl!
 
 Here's some inspiration for you....This is my girlfriend's '85 FJ600. Purchased from the original owner about 5 years ago with a stack full of service records, receipts, owners manual, tool kit...even a set of genuine Yamaha saddle bags that are color matched!
 Amazing bike and fast as hell. It was the world's fastest 600cc production bike in 1985.
 
(http://i190.photobucket.com/albums/z189/uberkafer/P2010093.jpg)
(http://i190.photobucket.com/albums/z189/uberkafer/P2010094.jpg)
(http://i190.photobucket.com/albums/z189/uberkafer/Photo0446.jpg)
 
 Check out xjbikes.com . Good forums for these bikes (the FJ was an XJ in Europe and the engine is basically the same as many of the other XJ models).
 
 Also, you mentioned something about the bars.... Did you know you can swap in a Radian top triple tree? It has risers and you can run almost any handlebar, then.
Title: Re: 1984 Yamaha FJ 600- Rise of "The Mighty Jig"
Post by: Kickeroo on Aug 26, 2011, 07:56:00
Will do.  Thanks.  I dig the Beetle, too.  (mine is a '00 1.8 GLS)
Title: Re: 1984 Yamaha FJ 600- Rise of "The Mighty Jig"
Post by: Kickeroo on Aug 27, 2011, 16:55:18
I changed out the clutch cable and was happy to see that the clutch assembly is much smooter than I originally thought.  Moved on to the great Carb Swap.  I yanked out the FJ's with no problem, and inspected them to see what I would need for the FZ carbs that a Facebook friend gave me.  Well, one significant difference is that it appears the FZ originally had a 3-prong gas intake piping arrangement versus the FJ's original single gas intake. So, it's back to the Microfiche world to see what it'll take to upgrade...beyond a few exta lenghts of fuel piping.  I'm guessing/hoping a one-in-three-out fitting exists?
Title: Re: 1984 Yamaha FJ 600- Rise of "The Mighty Jig"
Post by: Kickeroo on Sep 01, 2011, 08:59:28
Minor setback.  In  trying to see what was in the front brake reservoir, the cover screw stripped. Ok, no problem....I tried using a screw extractor.  Nope.  Didn't work.  So, I started drilling. I drilled out enough that I was able to remove the cover and the gasket.  Any leftover brake fluid has, well, turned to a white dusty powder.  I shop-vacc-ed that out.  Back to the stripped screw. I shot it with Liquid Wrench and let it sit for a good while.  Then I went back at it with the smallest screw extractor.  I thought I was making progress, when SNAP! As you can see from the picture, the hole on the left is now filled with a just-about-undrillable-hardened-steel-broken-screw-ectractor bit. Not that the reservoir, not any lines coming to it apear to be salvagable, due to the sublimation of the brake fluid to a brake solid.  A run to Pro Class (the local bike junkyard) is on the weekend schedule, since this style of brake was used by Yamaha quite a bit:
(http://i35.photobucket.com/albums/d151/Kickeroo/Rise%20of%20the%20FJ600/stuff002.jpg)
Pet Peeve: fittings.  There's is an underwhelming selection of available metric fittings in this town (Richmond VA).  I have a "kit" on the way to me from Amazon that gives me an assortment that may or may not be useful.  What's shown is an exhaust stud (Yamaha part number 90116-06466-00) that goes for $1.81 a piece.  Above is a hex-head metric machine screw that I believe would work for securing the exhaust header that I got from Lowe's for $2.07 a pair ($1.035 each).  By using this I would also eliminate the nut (Yamaha part number 90179-06500-00) at $2.02 each.  Now, I've cleaned up the fittinngs I have, but after 27 years on the job (accompanying rust), I think they deserve a retirement.  What I want to know is this: how "special" are the fittings I'm retiring?  Are they treated for such high-temp use such that everyday fittings would buckel and disintigrate, or have I fugured out the dirty little secret of nuts and bolts?
(http://i35.photobucket.com/albums/d151/Kickeroo/Rise%20of%20the%20FJ600/stuff005.jpg)
The exhaust header, awaiting the aforementioned fittings.  looks brand new, and is painted with the appropriate header paint
(http://i35.photobucket.com/albums/d151/Kickeroo/Rise%20of%20the%20FJ600/stuff006.jpg)
The old carbs from the FJ.  Maybe this winter, if all goes well, I'll clean em up, slap them on ebay and see what happens.
(http://i35.photobucket.com/albums/d151/Kickeroo/Rise%20of%20the%20FJ600/stuff007.jpg)
Title: Re: 1984 Yamaha FJ 600- Rise of "The Mighty Jig"
Post by: Kickeroo on Sep 05, 2011, 11:40:11
A little retrospect on how this project is proceeding. 
First, I finally received the title from PA.  I had forgotten BITD that I titled it to my soon-to-be-x's-parent's house that eventually was forclosed on.  I'm surprised I wasn't told to surrender the bike against back property liens!

Second, I did a little more research on the exhaust stems, and at the end of the day, I don't want to compromise the design intent, especially since Yamaha made one side of the stems M7, and the other side M6.  Nice...  So, Bike Bandit got the OEM business along with an red anodized aluminum fuel filter, some clear red fuel line and, because insurance is a wonderful thing, KREEM for the tank.
Another thing I bought along the way is a proper adjutible fork seal driver.  The Scrapple II project has a pair of post-77 forks that were given to me, so I'll try to get to those first.  This is something I HAVE to to learn how to do correctly if I'm going to eventally have 4 running bikes.
 
Title: Re: 1984 Yamaha FJ 600- Rise of "The Mighty Jig"
Post by: Griff5268 on Sep 05, 2011, 17:26:37
I've got one of those brake units if you need it. It just doesn't have the hole to screw in a mirror. You may be able to morph them into one unit...Email me if u need it man.
Title: Re: 1984 Yamaha FJ 600- Rise of "The Mighty Jig"
Post by: Griff5268 on Sep 05, 2011, 17:28:25
Check out my profile pic..Just added a filter myself but went with the clear blue line..It looks awesome under my white leds at night.. The Jig is coming together nicely.
Title: Re: 1984 Yamaha FJ 600- Rise of "The Mighty Jig"
Post by: Kickeroo on Sep 05, 2011, 20:23:11
I've got one of those brake units if you need it. It just doesn't have the hole to screw in a mirror. You may be able to morph them into one unit...Email me if u need it man.
I have an ongoing bid for one on ebay, but I will definitely get back to you on that.  Thanks!
Title: Re: 1984 Yamaha FJ 600- Rise of "The Mighty Jig"
Post by: Griff5268 on Sep 06, 2011, 09:35:56
Hell, just pay me for the shipping and this one's yours.. Let me know if ebay falls through.
Title: Re: 1984 Yamaha FJ 600- Rise of "The Mighty Jig"
Post by: regal7point5 on Sep 21, 2011, 10:36:10
Kickeroo, where in RVA are you?  I was in Midlo and just moved to Powhatan and have a 86 Radian.  I'd love to swing by or at least offer moral support, parts comparisons, etc if you need it.  Having a live running bike can be a great thing when rebuilding to compare components to.
 
Aaron
Title: Re: 1984 Yamaha FJ 600- Rise of "The Mighty Jig"
Post by: regal7point5 on Sep 21, 2011, 10:40:53
Nevermind...I just checked your profile and saw you are in the Reams Rd area.  I am in that area quite often...let me know if you need a hand.  You are a member of the Facebook group, RVA Cafe Moto Culture, right?  Good info and contacts on there as well.
 
Aaron
Title: Re: 1984 Yamaha FJ 600- Rise of "The Mighty Jig"
Post by: Kickeroo on Sep 21, 2011, 14:23:10
Kickeroo, where in RVA are you?  I was in Midlo and just moved to Powhatan and have a 86 Radian.  I'd love to swing by or at least offer moral support, parts comparisons, etc if you need it.  Having a live running bike can be a great thing when rebuilding to compare components to.
 
Aaron

I'm just off of Reams Road in Chesterfield, if that helps.
Title: Re: 1984 Yamaha FJ 600- Rise of "The Mighty Jig"
Post by: Kickeroo on Sep 21, 2011, 14:24:38
And yes, I'm on the RVA Cafe FB group.
Title: Re: 1984 Yamaha FJ 600- Rise of "The Mighty Jig"
Post by: Kickeroo on Sep 22, 2011, 18:20:28
I changed out the clutch cable and was happy to see that the clutch assembly is much smooter than I originally thought.  Moved on to the great Carb Swap.  I yanked out the FJ's with no problem, and inspected them to see what I would need for the FZ carbs that a Facebook friend gave me.  Well, one significant difference is that it appears the FZ originally had a 3-prong gas intake piping arrangement versus the FJ's original single gas intake. So, it's back to the Microfiche world to see what it'll take to upgrade...beyond a few exta lenghts of fuel piping.  I'm guessing/hoping a one-in-three-out fitting exists?
Yeah.... I didn't know what I was talking about.
 
Anyhooo....well it turns out that FZ 600's had 30mm carbs, and Good ol' FJ 600's had 32mm Mikunis.  Well then, that makes for some fitting issues I'm not too crazy about...so.....my old carbs are currently having a Simple Green soaking.  I'll rinse and dry them as best as I can, and if all goes swimmingly, then I'll move on to the rear swingarm and replacing fork seals. 
Title: Re: 1984 Yamaha FJ 600- Rise of "The Mighty Jig"
Post by: Kickeroo on Sep 23, 2011, 07:49:46
Other news...info trail on the 'net tells me that FZ racers back in the day often swapped ou their 30mm carbs for the 32mm carbs I have.  So I have THAT going for me, which is nice.
Title: Re: 1984 Yamaha FJ 600- Rise of "The Mighty Jig"
Post by: Kickeroo on Sep 26, 2011, 14:19:27
Ok....when I swapped out the relays gave a momentary push of the starter button, the starter cranked.
Now, with everything plumbed up (carbs, tank, etc).  i push the button, I get a clicking from the relay, and nothing from the starter.
HELP!!!!!!!
Title: Re: 1984 Yamaha FJ 600- Rise of "The Mighty Jig"
Post by: Bozz on Sep 26, 2011, 14:54:10
sounds like insufficient amperage from battery to crank engine against compression.

Is it possible that your test crank had the spark plugs removed?

Other possibility is too much resistance in the solenoid.  Try carefully shorting the 2 main solenoid (starter relay) wires with a screwdriver.

If the starter jumps when you short, it's the relay (solenoid).  If it still doesn't, then it is likely the battery.

Could also be the ground wire.  The battery usually grounds to the frame while the starter grounds through the engine cases.  Check ground strap between engine and frame as well as all ground connections for corrosion.
Title: Re: 1984 Yamaha FJ 600- Rise of "The Mighty Jig"
Post by: Kickeroo on Sep 27, 2011, 13:18:49
SUCESS!!! (ish).  Checked all of the grounds I could find, cleaned them.  Gave a polite tapping to the dodgy flash-relay unitl the neutral light came on.  And so...she cranked!   ....but didn't start. :(
I sprayed in a few puffs of started spray.  I got a few pops, but no real ignition. :-\
My fuel lines are a bit long and I saw that the one after the fuel filter I put in was kinking, so I'll adjust that in a bit.
All in all I'm encouraged. 8)
Title: Re: 1984 Yamaha FJ 600- Rise of "The Mighty Jig"
Post by: Kickeroo on Sep 27, 2011, 14:00:43
Fuel line sorted and now carbs 3 and 4 are leaking.  rats.
Title: Re: 1984 Yamaha FJ 600- Rise of "The Mighty Jig"
Post by: Kickeroo on Sep 29, 2011, 07:42:23
Carb kits ordered, and professional help has been recruited.
Onto fork seals, brakes, chain, tires and replacing all of the bearings and fitting in the wheels, and swingarm. 
Title: Re: 1984 Yamaha FJ 600- Rise of "The Mighty Jig"
Post by: raptor97321 on Sep 29, 2011, 11:02:34
What Carb Kits did you order? I have Carb #2 Leaking.  I was able to find a good deal on the Dynojet kit.
Title: Re: 1984 Yamaha FJ 600- Rise of "The Mighty Jig"
Post by: Kickeroo on Sep 30, 2011, 10:36:30
I see there are a number of Dynojet kits on ebay for under $100, not including shipping.  For the record, the kit number should be: #4107 for the Mikuni BS32 carbs.
As for the rebuild kit, K&L "economy" kit number 18-5105 is what their site says to use.  I'm a bit leary about anyone who mates up my FJ with a kit that does not disclose the kit number, or the designated carbs that the kit is designed for.  K&L does NOT have a kit in their 2011 catalog that also has any jets, so by default, the Dynojet kit will be ordered as well, even though, back in the day, I know for certain that a Dynojet kit is/was installed in my carbs from day 1, but it'd probably be in my best interest to replace them by this point, since I bought the bike in 1992.
Title: Re: 1984 Yamaha FJ 600- Rise of "The Mighty Jig"
Post by: Griff5268 on Oct 03, 2011, 10:43:56
Did you end up getting the brake lever/assembly issue figured out?
Title: Re: 1984 Yamaha FJ 600- Rise of "The Mighty Jig"
Post by: Kickeroo on Oct 04, 2011, 09:25:42
Yes.  new reservoir worked out ok.  Thanks!!
Title: Re: 1984 Yamaha FJ 600- Rise of "The Mighty Jig"
Post by: Kickeroo on Oct 11, 2011, 10:08:01
I have paused progress on my projects so that I can finally get my garage organized.  I went from this:
(http://a2.sphotos.ak.fbcdn.net/hphotos-ak-snc7/318348_10150308988007331_642117330_8245713_1047381594_n.jpg)
Title: Re: 1984 Yamaha FJ 600- Rise of "The Mighty Jig"
Post by: Kickeroo on Oct 11, 2011, 10:34:42
by way of a floor coating kit...to this:
(http://i35.photobucket.com/albums/d151/Kickeroo/Rise%20of%20the%20FJ600/Garage3004.jpg)
a bit better organized...but still not great;
(http://i35.photobucket.com/albums/d151/Kickeroo/Rise%20of%20the%20FJ600/Garage3005.jpg)
(http://i35.photobucket.com/albums/d151/Kickeroo/Rise%20of%20the%20FJ600/Garage3015.jpg)
the "Scrapple II" Honda CB550, on hold:
(http://i35.photobucket.com/albums/d151/Kickeroo/Rise%20of%20the%20FJ600/Garage3006.jpg)
(http://i35.photobucket.com/albums/d151/Kickeroo/Rise%20of%20the%20FJ600/Garage3011.jpg)
(http://i35.photobucket.com/albums/d151/Kickeroo/Rise%20of%20the%20FJ600/Garage3010.jpg)
(http://i35.photobucket.com/albums/d151/Kickeroo/Rise%20of%20the%20FJ600/Garage3012.jpg)
(http://i35.photobucket.com/albums/d151/Kickeroo/Rise%20of%20the%20FJ600/Garage3013.jpg)
And the star of this thread;
(http://i35.photobucket.com/albums/d151/Kickeroo/Rise%20of%20the%20FJ600/Garage3009.jpg)
other artifacts:
(http://i35.photobucket.com/albums/d151/Kickeroo/Rise%20of%20the%20FJ600/Garage3014.jpg)
 
Title: Re: 1984 Yamaha FJ 600- Rise of "The Mighty Jig"
Post by: jbrtwork on Oct 14, 2011, 17:04:59
Luvin' this thread. The rust in the tank and cruddy carbs are very familiar. This FJ seems somewhat similar to my '93 XJ600 Seca II cafe project. Got it from my son-in-law. Sat for six or seven years - allegedly, the engine had seized. Not so. I got it to spin over when I try to start it, but so far no spark. It's been sitting again while I've been playing with my V-Star.


Keep up the good work. This may be the motivation I need to get back to it.
Title: Re: 1984 Yamaha FJ 600- Rise of "The Mighty Jig"
Post by: Kickeroo on Jan 12, 2012, 08:16:05
Project not dead, far from it.  Bit the bullet on listing the "Scrapple" project on CL, and it may go this weekend. If so, well, any and all procees will go into finishing The Mighty Jig.  I bought a used Flasher relay on ebay recently, and that seems to have cured the intermittent electrical issues.  Still I have a ways to go, including, yes, the carbs, stiffening up the replacement fairing I bought, sorting out brakes, replacing all of the bushings in the rear swingarm, a new shock, fork seals (have), new tires (stalking on ebay and Amazon, of all places), and getting a new seat cover.  The stripped bar-end weights are still firmly in place and will need to be gone if i'm ever going to be able to put new grips on it.   

In other news, I had finally gotten its long lost Pennsyltuckey title in a the mail and on 12/28/22, lest I have to pay any 2011 Virginia Property taxes, it now has a clear, clean and legal Virginia title.

Have a little faith, my brothers and sisters.
Title: Re: 1984 Yamaha FJ 600- Rise of "The Mighty Jig"
Post by: Griff5268 on Jan 12, 2012, 10:10:41
What's that Carbon Windscreen fit?
Title: Re: 1984 Yamaha FJ 600- Rise of "The Mighty Jig"
Post by: Kickeroo on Jan 12, 2012, 12:12:39
The '01 Guzzi V11 Sport, but it's gone.
Title: Re: 1984 Yamaha FJ 600- Rise of "The Mighty Jig"
Post by: Kickeroo on Jan 30, 2012, 09:04:15
Some pictures to chew on...

Yeah...I've had enough of this particular 'rasslin match;
(http://i35.photobucket.com/albums/d151/Kickeroo/Rise%20of%20the%20FJ600/FJwork002.jpg)

Credit to one of my GF's old BF.  He left a saws-all behind.  Thanks babe!
(http://i35.photobucket.com/albums/d151/Kickeroo/Rise%20of%20the%20FJ600/FJwork004.jpg)

The bar to go with it;
(http://i35.photobucket.com/albums/d151/Kickeroo/Rise%20of%20the%20FJ600/FJwork006.jpg)

it's $9 ebay replacement;
(http://i35.photobucket.com/albums/d151/Kickeroo/Rise%20of%20the%20FJ600/FJwork008.jpg)

Some Simple Green
(http://i35.photobucket.com/albums/d151/Kickeroo/Rise%20of%20the%20FJ600/FJwork009.jpg)

Works wonders!
(http://i35.photobucket.com/albums/d151/Kickeroo/Rise%20of%20the%20FJ600/FJwork011.jpg)

Do dealerships still put their sticker on bikes after servicing?
(http://i35.photobucket.com/albums/d151/Kickeroo/Rise%20of%20the%20FJ600/FJwork013.jpg)

I must have weighed a ton to be able to do this...
(http://i35.photobucket.com/albums/d151/Kickeroo/Rise%20of%20the%20FJ600/FJwork015.jpg)

Really...the fork seals are still good.....but I know, I know....
(http://i35.photobucket.com/albums/d151/Kickeroo/Rise%20of%20the%20FJ600/FJwork017.jpg)

No comment. 
(http://i35.photobucket.com/albums/d151/Kickeroo/Rise%20of%20the%20FJ600/FJwork021.jpg)

Coming soon from ebay:
(http://i35.photobucket.com/albums/d151/Kickeroo/Rise%20of%20the%20FJ600/FJwork022.jpg)

OEM price is about $126
(http://i35.photobucket.com/albums/d151/Kickeroo/Rise%20of%20the%20FJ600/FJwork023.jpg)

OEM price for the missing damper is over $9!!!
(http://i35.photobucket.com/albums/d151/Kickeroo/Rise%20of%20the%20FJ600/FJwork024.jpg)
Title: Re: 1984 Yamaha FJ 600- Rise of "The Mighty Jig"
Post by: Griff5268 on Jan 30, 2012, 13:50:15
I have a set of Yamaha front signals off my radian if interested let me know..
Title: Re: 1984 Yamaha FJ 600- Rise of "The Mighty Jig"
Post by: Kickeroo on Jan 31, 2012, 14:58:17
Maybe....there's a lot of them nearby at the local junkyard..

Cool stuff to go in....
(http://i35.photobucket.com/albums/d151/Kickeroo/Rise%20of%20the%20FJ600/bitsandpieces003.jpg)

My replacement fairing, needing a little TLC to firm up a few areas, waiting patiently in my loft:
(http://i35.photobucket.com/albums/d151/Kickeroo/Rise%20of%20the%20FJ600/bitsandpieces004.jpg)

The forks, of which I have new seals, a seal tool,  and a service manual.  I'll get to these once the front wheel bearings are out and replaced.  Only one problem with that...,

I CAN'T GET THE FREAKING OLD BEARINGS OUT (yet)
(http://i35.photobucket.com/albums/d151/Kickeroo/Rise%20of%20the%20FJ600/bitsandpieces005.jpg)
Title: Re: 1984 Yamaha FJ 600- Rise of "The Mighty Jig"
Post by: Kickeroo on Feb 02, 2012, 11:51:27
What you're looking at right here is actual progress.  Still it took one trip to Sears (for the wring kind of puller) and one trip to Harbor Freight (for the right puller).  At the end of the day, with exception to the 20-year old Metzler that still is on it, the front wheel has all new bearings and hey, cleaned up pretty well (Simple Green...again)
(http://i35.photobucket.com/albums/d151/Kickeroo/Rise%20of%20the%20FJ600/wheelsandbits001.jpg)

Onto the next phase, which is dissassembling the forks, something I have never done before.  There's the 17mm hex cap bolt that, once undone, all hell breaks loose;
(http://i35.photobucket.com/albums/d151/Kickeroo/Rise%20of%20the%20FJ600/wheelsandbits002.jpg)

And the impact bit and torque wrench that loosened it:
(http://i35.photobucket.com/albums/d151/Kickeroo/Rise%20of%20the%20FJ600/wheelsandbits003.jpg)

Shown is the lower for brace.  What is a good way of cleaning this up, i.e. getting rid of that yellowish patina.  Is that the aluminium's original clear coat, or what?  I'll take suggestions.
(http://i35.photobucket.com/albums/d151/Kickeroo/Rise%20of%20the%20FJ600/wheelsandbits006.jpg)
Title: Re: 1984 Yamaha FJ 600- Rise of "The Mighty Jig"
Post by: NoHonestlyitsme on Feb 08, 2012, 00:14:55
bring it back to life. Nice to see a bike restored by its Owner from back in the day rather than buying a bike from the previous owner and restoring it like every other build.
Title: Re: 1984 Yamaha FJ 600- Rise of "The Mighty Jig"
Post by: Kickeroo on Feb 08, 2012, 09:51:51
After MUCH light-sanding and MOTHER'S polish, the fork brace looks much better....which also means I've just opened a can of worms in regards to refurbushing all of the other aluminum parts on this old girl:
(http://i35.photobucket.com/albums/d151/Kickeroo/Rise%20of%20the%20FJ600/update002.jpg)

use it, love it, live it.  The passenger grab rail will be addressed in due time:
(http://i35.photobucket.com/albums/d151/Kickeroo/Rise%20of%20the%20FJ600/update008.jpg)

The first of the ones I truly don't remember ordering;
(http://i35.photobucket.com/albums/d151/Kickeroo/Rise%20of%20the%20FJ600/update004.jpg)

which means, later today I get to 'rassle this.....something I've never done before either:
(http://i35.photobucket.com/albums/d151/Kickeroo/Rise%20of%20the%20FJ600/update005.jpg)
Title: Re: 1984 Yamaha FJ 600- Rise of "The Mighty Jig"
Post by: Kickeroo on May 11, 2012, 10:29:55
Ok...Update time.  Work throughout March and most of April was ZERO due to an ongoing personal issue regarding my soon-to-be-ex, my AWESOME daughter, and lawyers.  Understandable to say the least.

First up, or, er, off: the steering stem/triple tree: I had to elist some help to get the lower bearing race off.
(http://i35.photobucket.com/albums/d151/Kickeroo/Rise%20of%20the%20FJ600/bearingraceonstem001.jpg)

And how it looks this morning in my outdoor rattle can paint booth:
(http://i35.photobucket.com/albums/d151/Kickeroo/Rise%20of%20the%20FJ600/fjstateoftheproject001.jpg)

When the paint is dry, I'll be able to continue to put the FRONT back together:
(http://i35.photobucket.com/albums/d151/Kickeroo/Rise%20of%20the%20FJ600/fjstateoftheproject003.jpg)

Forks have new seals...finally
(http://i35.photobucket.com/albums/d151/Kickeroo/Rise%20of%20the%20FJ600/fjstateoftheproject014.jpg)

And an All-balls kit is ready to go in as well:
(http://i35.photobucket.com/albums/d151/Kickeroo/Rise%20of%20the%20FJ600/fjstateoftheproject015.jpg)

While the forks were out, and, well, I needed to take out some frustration, I started taking apart the rear wheel.  Needless to say, it's a mess back here:
(http://i35.photobucket.com/albums/d151/Kickeroo/Rise%20of%20the%20FJ600/fjstateoftheproject005.jpg)

Really:
(http://i35.photobucket.com/albums/d151/Kickeroo/Rise%20of%20the%20FJ600/fjstateoftheproject004.jpg)

That's about 20 years of grime on there.  Can you say PRESSURE WASHER??
(http://i35.photobucket.com/albums/d151/Kickeroo/Rise%20of%20the%20FJ600/fjstateoftheproject006.jpg)

PROGRESS: Cleaned up the rear socket and boot assembly:
(http://i35.photobucket.com/albums/d151/Kickeroo/Rise%20of%20the%20FJ600/fjstateoftheproject010.jpg)

And earlier last week, the fairing-stay gor a new coat of Krylon:
(http://i35.photobucket.com/albums/d151/Kickeroo/Rise%20of%20the%20FJ600/fjstateoftheproject013.jpg)

And I'm keeping everything else organized...to an extent with these bins I got at Home Depot for $1 each:
Handlebar assembly bin:
(http://i35.photobucket.com/albums/d151/Kickeroo/Rise%20of%20the%20FJ600/fjstateoftheproject016.jpg)

Triple tree and forks bin:
(http://i35.photobucket.com/albums/d151/Kickeroo/Rise%20of%20the%20FJ600/fjstateoftheproject017.jpg)

Rear Wheel bin:
(http://i35.photobucket.com/albums/d151/Kickeroo/Rise%20of%20the%20FJ600/fjstateoftheproject018.jpg)

And the rear wheel itself (not cleaned or devoid of its crustry old Dunlop yet)
(http://i35.photobucket.com/albums/d151/Kickeroo/Rise%20of%20the%20FJ600/fjstateoftheproject012.jpg)

And no project thread is completer without a shot of a rusty old chain...which, with exception of MAYBE a few bushings, fittings, and other odd lots is the only thing MAJOR that I need to replace anytime soon:
(http://i35.photobucket.com/albums/d151/Kickeroo/Rise%20of%20the%20FJ600/fjstateoftheproject008.jpg)

OK, maybe brake pads and replacment lines...but no, really, that's all I need, I swear:
(http://i35.photobucket.com/albums/d151/Kickeroo/Rise%20of%20the%20FJ600/fjstateoftheproject009.jpg)

Thanks for looking
Title: Re: 1984 Yamaha FJ 600- Rise of "The Mighty Jig"
Post by: Maritime on May 11, 2012, 10:39:27
Nice work, I am about to attempt my first tire change, fork oil change etc. on my 79 GL1000.  Let us know how it goes for you on those tires.  Amazing what a little wet sand and mothers can do for crusty aluminum.  Give it at least a few coats of car wax or if you can find it a product called sharkskin can protect it really well.  I am still trying to obtain an bottle of that for my polished bits.  I spent hours on it and with the weather around me it will look terrible in a couple days if I don't do something to protect it.

Cheers
Title: Re: 1984 Yamaha FJ 600- Rise of "The Mighty Jig"
Post by: Bozz on May 11, 2012, 12:49:52
Lookin good so far!


The secret to tires is making sure the opposite side of the bead stays down in the well of the wheel when you spoon it off/on the rim.
That and a dash of soapy water.


An extra pair of hands helps a LOT if you can get them.
Title: Re: 1984 Yamaha FJ 600- Rise of "The Mighty Jig"
Post by: Maritime on May 11, 2012, 13:06:06
I also read to be careful with what brand/kind of soap as some is caustic/acidic and can eat holes in alloy wheels.  Cause slow leaks and inproper beat seating. I bought tire intallation lube designed to be safe on all types of metal wheels. it was 6 bucks for a lifetime supply.
Title: Re: 1984 Yamaha FJ 600- Rise of "The Mighty Jig"
Post by: Yamatech on May 13, 2012, 12:31:17
Id change the sprockets along with the chain only because your new chain will wear more quickly to already worn sprockets. But its not critical just some insite.
Title: Re: 1984 Yamaha FJ 600- Rise of "The Mighty Jig"
Post by: Kickeroo on May 18, 2012, 17:23:41
So, at the advise of, well, everyone, new front and rear sprockets are on order (16 front, 45 rear, factory spec)

Here's the dirty mess behind the sprocket cover:
(http://i35.photobucket.com/albums/d151/Kickeroo/Rise%20of%20the%20FJ600/FJgears003.jpg)

Sprocket doesn't look tooooo challenging:
(http://i35.photobucket.com/albums/d151/Kickeroo/Rise%20of%20the%20FJ600/FJgears002.jpg)

And the gunk that collected over the years (currently soaking in Simple Green)
(http://i35.photobucket.com/albums/d151/Kickeroo/Rise%20of%20the%20FJ600/FJgears001.jpg)

And YET AGAIN, while reassembing the slave cylinder/horn mount, I sheared off the hex-fitting.  I'll be drilling thisn one out for a while:
(http://i35.photobucket.com/albums/d151/Kickeroo/Rise%20of%20the%20FJ600/FJgears006.jpg)

Thanks for looking
Title: Re: 1984 Yamaha FJ 600- Rise of "The Mighty Jig"
Post by: gentlemanjim on Jun 05, 2012, 05:19:22
I'm thoroughly enjoying this project.  Always loved the FJ600's.  After 34 bikes maybe someday I'll get to rebuild one.  As far polidhing up htr aluminum CAsewell has sanding paste in various grits from 180 to 600 and them polishing sticks.  They work extremely well and fast worth getting.  Check them out lots of other cool stuff as well. http://www.caswellplating.com/buffing-polishing/buffing-compounds.html
Title: Re: 1984 Yamaha FJ 600- Rise of "The Mighty Jig"
Post by: Kickeroo on Jun 07, 2012, 12:06:01
I guess I can afford to show some progress:

Front wheel is back on (all new wheel bearings):
(http://i35.photobucket.com/albums/d151/Kickeroo/Rise%20of%20the%20FJ600/intenttofinish001.jpg)

I wound up comrimising on the stuck/sheared fastener.  Ok, so I used a zip-tie.
(http://i35.photobucket.com/albums/d151/Kickeroo/Rise%20of%20the%20FJ600/intenttofinish002.jpg)

Rear tire mounted (by hand!) note new rear sprocket (and all new wheel bearings, here, too):
(http://i35.photobucket.com/albums/d151/Kickeroo/Rise%20of%20the%20FJ600/intenttofinish003.jpg)

New Front sprocket, too.  A lot cleaned up, as well:
(http://i35.photobucket.com/albums/d151/Kickeroo/Rise%20of%20the%20FJ600/intenttofinish004.jpg)

Inside of the sprocket-cover case cleaned up satisfactorally:
(http://i35.photobucket.com/albums/d151/Kickeroo/Rise%20of%20the%20FJ600/intenttofinish005.jpg)

Handle-bar bolt covers are hard to come by.  So, instead, I found these $1 1" grommet covers at Home depot.
(http://i35.photobucket.com/albums/d151/Kickeroo/Rise%20of%20the%20FJ600/intenttofinish006.jpg)

The $9 exterior grommet for the guage cluster I fashioned out of some rubber plug I found when I was walking my dog:
(http://i35.photobucket.com/albums/d151/Kickeroo/Rise%20of%20the%20FJ600/intenttofinish007.jpg)

Front fender chip:  I'm sort of stuck with it, but hey, I never said I was bringing it back to showroom condition, right?
(http://i35.photobucket.com/albums/d151/Kickeroo/Rise%20of%20the%20FJ600/intenttofinish008.jpg)
Title: Re: 1984 Yamaha FJ 600- Rise of "The Mighty Jig"
Post by: JustinLonghorn on Jun 07, 2012, 13:17:33
Nice progress, man!
Title: Re: 1984 Yamaha FJ 600- Rise of "The Mighty Jig"
Post by: Kickeroo on Nov 25, 2012, 20:00:08
Question for those in the know...

...my buddy who'd rebuilding my carbs says that he needs " I need one needle assembly and one enrichening circuit assembly".  Can anyone tell me from the attached schematic what items he's talking about? (note, the attached schematic is not exactly the one I'd be ordering parts from)

http://www.nwvcp.com/pages/OemParts?aribrand=YAM#/Yamaha/FJ600L_-_1984/CARBURETOR/FJ600L_(1984_MOTORCYCLE)/CARBURETOR_(FJ600L_-_1984) (http://www.nwvcp.com/pages/OemParts?aribrand=YAM#/Yamaha/FJ600L_-_1984/CARBURETOR/FJ600L_(1984_MOTORCYCLE)/CARBURETOR_(FJ600L_-_1984))
Title: Re: 1984 Yamaha FJ 600- Rise of "The Mighty Jig"
Post by: Yamatech on Nov 26, 2012, 15:04:58
usually when someone says needle assemblys i assume they are talking about the needle valve and seat which the float is attached to so in that case, that is number 10. and as for the enrichning circuit assembly id assume he is talking about the starter set which is number 24. So many people call things different names its hard to tell so try to get some more info from him just to be sure. I just looked up parts for your bike here at the shop directly from yamaha, it seems that is the same diagram we have as the one you are showing and the same names of parts so just double check with him.
Title: Re: 1984 Yamaha FJ 600- Rise of "The Mighty Jig"
Post by: Kickeroo on Feb 01, 2013, 11:14:07
PROJECT IS NOT DEAD!

Getting to the dirty stuff, at last! Rear shock and swingarm removed.  I have SOME parts that I pre-bought on reccommendations of stuff that usually needs replacing.
 
Got the word from my buddy (Brooks cycle center, in Northern VA) that the carbs are ready to ship, thus, the reason I go my tail into gear to go over the hindquarters.
 
One other project is to use some 3M plastic cement and web-type-stuff to strengthen the mouting tabs on the new-to-me replacement fairing I bought about a year ago.  With the age of the stuff, the ABS is probably leaning towards being brittle, so I think that looking into a way to bolster it up without going redneck (i.e. duct tape) on it would be in my best interest.

See if you can spot the $50 in this picture.

(http://i35.photobucket.com/albums/d151/Kickeroo/Rise%20of%20the%20FJ600/fjrearwork010.jpg)

If you guessed THIS part, you win.  It's the rear shock adustment belt (Yamaha part number 33M-22266-00-00) that is about $50 shipped, no matter where I get it from.

(http://i35.photobucket.com/albums/d151/Kickeroo/Rise%20of%20the%20FJ600/fjrearwork011.jpg)


Why it has to be replaced.
(http://i35.photobucket.com/albums/d151/Kickeroo/Rise%20of%20the%20FJ600/fjrearwork013.jpg)

The swing arm, pre-gumk removed.  it's about 35 degrees out, and I'm about to take a pressure washer to it.

(http://i35.photobucket.com/albums/d151/Kickeroo/Rise%20of%20the%20FJ600/fjrearwork014.jpg)

The rear shock.  There's still some blue paint on the spring.  Really.
(http://i35.photobucket.com/albums/d151/Kickeroo/Rise%20of%20the%20FJ600/fjrearwork015.jpg)

One word.  yuk.
(http://i35.photobucket.com/albums/d151/Kickeroo/Rise%20of%20the%20FJ600/fjrearwork016.jpg)
Title: Re: 1984 Yamaha FJ 600- Rise of "The Mighty Jig"
Post by: Yamatech on Feb 06, 2013, 10:41:18
Thats the kind of mess that makes me not even want to touch things sometimes and say screw it where's the parts book. God speed sir!
Title: Re: 1984 Yamaha FJ 600- Rise of "The Mighty Jig"
Post by: alph on Apr 26, 2013, 21:25:38
Kickeroo!!  i've got the same cycle!!  this last winter i rebuilt the carbs, put everything together and she started!!  ran really rough though, the carbs need to be synced.  took it out for a ride, got to the edge of the yard and hit a patch of ice!!  now i've got a right turn signal to replace.... 

looks like you're doing a heck of a nice job!  look forward in hearing a final update, or the first ride of the season.

my daughter wants this old bike, she's been nagging me for a year now, she's going to be 17 this may, i'll be signing her up for cycle riding classes for her present, DON'T ANYONE TELL HER THOUGH!!  she asked me today to teach her how to ride 'cause she's so jellous of seeing all the other cycles out today.  today was our first 70* day of the year...

here's mine, it's an old photo, but other than a broken right turn signal, pretty much the same.;

(http://i672.photobucket.com/albums/vv84/lavorata/cycle%20pictures/yamaha.jpg)
Title: Re: 1984 Yamaha FJ 600- Rise of "The Mighty Jig"
Post by: Kickeroo on Sep 20, 2013, 13:00:32
Ok, kids, and kittens....it's a milestone day.

Long story short....had to sell my Thruxton to pay bills, my 01 V11 Sport is in hospital with a total engine rebuild, so my attention turned back to this old girl.

10 AM EST, after 17+ years of being ignored, forgotten and written off.
http://www.youtube.com/watch?v=wCzXyULJbWI (http://www.youtube.com/watch?v=wCzXyULJbWI)

It's revving like hell, and I'm turning the idle adjuster to no avail.  Any suggestions?
Title: Re: 1984 Yamaha FJ 600- Rise of "The Mighty Jig"
Post by: ApriliaBill on Sep 20, 2013, 13:14:11
I've had this happen many times. go back and make sure the carbs. are ceaded right in the intakes and that you didn't over tighten the clamps. It's a vaccum leak and it is 99% at the intake. also did you at least bench sync the carbs.?
Title: Re: 1984 Yamaha FJ 600- Rise of "The Mighty Jig"
Post by: ApriliaBill on Sep 20, 2013, 13:19:02
PROJECT IS NOT DEAD!

Getting to the dirty stuff, at last! Rear shock and swingarm removed.  I have SOME parts that I pre-bought on reccommendations of stuff that usually needs replacing.
 
Got the word from my buddy (Brooks cycle center, in Northern VA) that the carbs are ready to ship, thus, the reason I go my tail into gear to go over the hindquarters.
 
One other project is to use some 3M plastic cement and web-type-stuff to strengthen the mouting tabs on the new-to-me replacement fairing I bought about a year ago.  With the age of the stuff, the ABS is probably leaning towards being brittle, so I think that looking into a way to bolster it up without going redneck (i.e. duct tape) on it would be in my best interest.

See if you can spot the $50 in this picture.

How about taking that belt over to NAPA and have them look. Probably something you could order. I buy lots of "motorcycle" parts from NAPA. They think I'm nuts when I walk through the door, but you'd be surprised how many times I find stuff I can make work. I have a 84 FJ600, it doesn't have that belt, maybe p.o. swapped the shock...

(http://i35.photobucket.com/albums/d151/Kickeroo/Rise%20of%20the%20FJ600/fjrearwork010.jpg)

If you guessed THIS part, you win.  It's the rear shock adustment belt (Yamaha part number 33M-22266-00-00) that is about $50 shipped, no matter where I get it from.

(http://i35.photobucket.com/albums/d151/Kickeroo/Rise%20of%20the%20FJ600/fjrearwork011.jpg)


Why it has to be replaced.
(http://i35.photobucket.com/albums/d151/Kickeroo/Rise%20of%20the%20FJ600/fjrearwork013.jpg)

The swing arm, pre-gumk removed.  it's about 35 degrees out, and I'm about to take a pressure washer to it.

(http://i35.photobucket.com/albums/d151/Kickeroo/Rise%20of%20the%20FJ600/fjrearwork014.jpg)

The rear shock.  There's still some blue paint on the spring.  Really.
(http://i35.photobucket.com/albums/d151/Kickeroo/Rise%20of%20the%20FJ600/fjrearwork015.jpg)

One word.  yuk.
(http://i35.photobucket.com/albums/d151/Kickeroo/Rise%20of%20the%20FJ600/fjrearwork016.jpg)
Title: Re: 1984 Yamaha FJ 600- Rise of "The Mighty Jig"
Post by: Kickeroo on Sep 23, 2013, 14:35:53
I've been checking, and checking and checking for a source of a vacuum leak.

Carbs are evenly installed, so they are not crooked in the inlets.

The vacuum lines (from carbs 1 and 4) back to the fuel petcock are intact.  The shared vacuum pressurization lines (carbs 2 and 3) do not seem to be compromised

There is nothing (i.e. the choke cable) putting any "pull" on the throttle cable

The clamps on the inlets seem to be snug, but I don't have anything other than "feel" to determine if they are too tight, too loose, or just right.

But still the bike comes to life screaming.

Is there something obvious I am missing?
Title: Re: 1984 Yamaha FJ 600- Rise of "The Mighty Jig"
Post by: Bozz on Sep 24, 2013, 10:17:12
It is very possible that something didn't get reassembled correctly in the carbs.
Slides could be spun out of alignment, main needles could have a washer below rather than above, you can swap air/fuel jets on some carbs too.
If you separated them, you could have the synch linkage wrong with 2 washers on 1 side rather than sandwiched.
Your choke linkage could be wrong.  (buddy scored a cheap bike that didn't run because the choke lever was mis-assembled.  20 min later it ran great)


You get the point.  There are a lot of tiny parts and it is easy to make a mistake.


First, I'd try leaving the carbs in the bike but disconnecting the throttle and choke cables from them.
Then see if the idle adjustment will work for you.  (removing possible culprits, trying to isolate the issue to the component level at least.)
If no change, then pull the carbs and get to work.


Don't panic.


This is actually good news, because it RUNS!  so you know it's likely not an ignition issue, or valve timing or any of the other systems.


This is almost certainly a carb/air leak issue.  (but sometimes throttle cable issues can disguise themselves as carb issues, so pull them out of the equation to make sure)


Take your time and be methodical.  You'll find it.


So nice to see one of these coming back to life.  Well done!


Good luck!
Title: Re: 1984 Yamaha FJ 600- Rise of "The Mighty Jig"
Post by: Kickeroo on Sep 24, 2013, 20:04:23
It's 99% the throttle cable, from what I can ascertain.


Idling like an angry kitten now.  Purrrfect
Title: Re: 1984 Yamaha FJ 600- Rise of "The Mighty Jig"
Post by: Bozz on Sep 26, 2013, 11:19:47
Eggggselent!


Minor bullet dodged.  Onward and upward!
Title: Re: 1984 Yamaha FJ 600- Rise of "The Mighty Jig"
Post by: Kickeroo on Sep 26, 2013, 22:26:51
Now to tackle the incidental intermittent electrical issues
Title: Re: 1984 Yamaha FJ 600- Rise of "The Mighty Jig"
Post by: Kickeroo on Sep 27, 2013, 18:39:10
All electrics, with exception to brake lights, are present and accounted for.

It was 21 years ago TOMORROW that, with $500 cash and a vague idea of used bike shops around the Philadelphia area, I set out to find something new-to-me.  That $500 turned out to be a down payment on $1600, but you get the idea.

Anyway,  I decided to put my better judgment on the shelf and take it for a lap around the neighborhood.  Fortunately, my GoPro decided to come along.

Quick review: Steering is SUPER LIGHT, and, well, feels a bit off centered.  This bike was punted by a garbage truck in 94, but outside of cosmetics, I never thought there was any frame damage.

Could be I'm just spoiled with how great my Thruxton was, and V11 Sport is...or at least as I remember it.

It's a fun little video, to me at least.  Song makes me tear up every time.
http://www.youtube.com/watch?v=BzBejImtsQg (http://www.youtube.com/watch?v=BzBejImtsQg)
Title: Re: 1984 Yamaha FJ 600- Rise of "The Mighty Jig"
Post by: Kickeroo on Oct 03, 2013, 16:51:46
Would anyone have a clue as to WHY I have, what I'll call, an intermittent starter motor? Sometimes the bike cranks, sometimes it doesn't. Starter relay sounds like its doing its thing, and all other parameters (bike in neutral, start switch on, key turned) are accounted for. Is there an optimal voltage I need to keep charging into the battery? Does the old-school "hit the starter motor with a hammer" trick apply here? Just curious.
Title: Re: 1984 Yamaha FJ 600- Rise of "The Mighty Jig"
Post by: Bozz on Oct 03, 2013, 17:15:31
IF you bridge the solenoid will it spin every time?
Sometimes the solenoids will corrode internally, and depending on exactly where the plates inside make contact you may get a connection, and you may not.
The solenoid will click every time, but the starter doesn't always engage.
Also, check your grounds carefully.
THe starter motor grounds through the motor and the frame back to the battery negative.
New Paint/powder can sometimes affect the electrical continuity between the pieces.
Handlebar controls also corrode over time, so inspect the contacts inside the starter button too.
Title: Re: 1984 Yamaha FJ 600- Rise of "The Mighty Jig"
Post by: Kickeroo on Oct 04, 2013, 16:03:07
Amazing what a pocket voltage detector and a loose ground wire will discover sometimes.... (slapping forehead)
Title: Re: 1984 Yamaha FJ 600- Rise of "The Mighty Jig"
Post by: Kickeroo on Nov 26, 2013, 22:43:09
I have to sell this......sadly.  Let me know if anyone is interested.
Title: Re: 1984 Yamaha FJ 600- Rise of "The Mighty Jig"
Post by: Big Chuck on Aug 24, 2015, 03:52:04
Old FJ's ... the don't just fade away ... they keep coming back from the dead!

Seems the FJ600 I found on the 'list is none other than Kickeroo's long lost FJ600 project!
(http://i51.photobucket.com/albums/f377/fastcoasty/Bikes/WP_20150811_002_zpsedfehfpq.jpg)
Time to revive an old thread?
I didn't even know the 600's existed until I found this one. I came across it while looking for a nice FJ1100 or 1200 to use as a daily driver. I had an 1100 many years ago and it was a comfortable highway bike.
Didn't take me long looking about the internet to figure out what it was, and to see the potential it had for a clean cafe project.
It was up for barter, so I offered a trade, and a day later it was in my truck!

The starter solenoid was removed (and missing) but I was assured it would run (I had heard that before, but the tags were still current and it had been inspected the year before, so couldn't be but so bad) and I took a chance.
Charged the battery for an hour, touched starter wires together and ... BAM! She fired right up!

http://vid51.photobucket.com/albums/f377/fastcoasty/Bikes/WP_20150811_010_zpsjqmk6lza.mp4

Sound on the video doesn't do it justice ... it has such a sweet sound coming from the Vance and Hines!
I have replaced the starter solenoid, so it starts every time now (and she starts very easy, even cold) and run it up and down the street a few times.
All the lights work, the brakes work (but one rotor is a bit wacked) and it shifts good. Runs well, even though it has pods, so it must be jetted correctly for them.
Right now I have the front apart, waiting for another rotor to show up, and rebuilding the forks. Forks were really "mushy" and rather soft, but I am 6'5" and 270 lbs. so I am used to working on forks and shocks on any motorcycle I want to ride for any length of time. We shall see how they turn out.

I am in a quandary right now about what direction to take with the bike.

When I first looked it up, I was dead set on doing a cafe looking bike, and they do make nice looking ones.
But looking through images on google I came across this bike,
(http://i51.photobucket.com/albums/f377/fastcoasty/Bikes/AJXJ-2-604x403_zpsv6uoptme.jpg)
and I really like yellow, and always liked the "competition yellow" Yamaha's.

Eventually I came across pictures of the RZ350's that inspired that bike ...
(http://i51.photobucket.com/albums/f377/fastcoasty/Bikes/Index%20of%20_images_thumb_b_b0_1985-Yamaha-RZ350-Yellow-4_zps0n1cdaro.jpg)

and if you look really close, that looks a LOT like the profile of an FJ600!
(http://i51.photobucket.com/albums/f377/fastcoasty/Bikes/IMG_2535_zps51qav4xo.jpg)

So now I am thinking ... make an FJ that looks like an RZ? Besides paint, it's a fairing and a few details from a very close copy.
No matter what, its a nice old bike that deserves to live on just a little bit longer!





Title: Re: 1984 Yamaha FJ 600- Rise of "The Mighty Jig"
Post by: Matt Rain on Aug 25, 2015, 21:18:59

(http://i51.photobucket.com/albums/f377/fastcoasty/Bikes/AJXJ-2-604x403_zpsv6uoptme.jpg)

I'm happy with my stock-ish FJ but that is an outstanding build. Wow.

Quote
No matter what, its a nice old bike that deserves to live on just a little bit longer!

Hear hear! I use mine daily to commute to work, love this quirky old thing.

(http://i.imgur.com/0RJohHc.jpg)

Best of luck with whatever you decide to do! I'll be keeping an eye on this thread.
Title: Re: 1984 Yamaha FJ 600- Rise of "The Mighty Jig"
Post by: Big Chuck on Aug 26, 2015, 05:41:26
Quote
Best of luck with whatever you decide to do! I'll be keeping an eye on this thread.

Thanks!

As soon as I get a rotor in I should have the front end back together and an update, new pictures. Should have had one (a rotor) by now, but somehow it didn't get paid for yet.
Seems we have one of those "rolling expense accounts", where when I need a bike part we are fresh out of extra money, but as soon as I tear out some cabinets in the kitchen, we are on our way to Home Depot for new ones. :o
If it were up to me, we'd live in a trailer out behind a garage the size of a small warehouse. All this washing, mowing, raking, painting and occasional remodeling crap takes too much time and money away from my habits... I mean hobbies!

On a side note, I have thought about the red and black paint job on your bike if I decide to go back to stock. It looks good, and I have found the full decal set for that color combo reproduced in new vinyl for about $90.
If they made it in the colors for mine, I might be pushed that way even more.
Title: Re: 1984 Yamaha FJ 600- Rise of "The Mighty Jig"
Post by: Big Chuck on Aug 28, 2015, 05:30:21
Managed to do a few small things ...

Broke out my cheesy DIY sand blasting box,
(http://i51.photobucket.com/albums/f377/fastcoasty/Bikes/WP_20150827_001_zps3wdatf6c.jpg)

Blasted the front wheel while it was off, and painted it with "Graphite" wheel paint.
(http://i51.photobucket.com/albums/f377/fastcoasty/Bikes/WP_20150823_003_zps6koj347k.jpg)
Not 100% sure about the color, but I tried polishing parts of the rim before I resorted to blasting it, but it just needed too much work.

Blasted the fork tubes as well,
(http://i51.photobucket.com/albums/f377/fastcoasty/Bikes/WP_20150827_002_zps3fcvidoy.jpg)
Then put a few coats of "Stainless Steel" on them,
(http://i51.photobucket.com/albums/f377/fastcoasty/Bikes/WP_20150827_005_zpsoxl22ksh.jpg)
Its an Epoxy "High solids" paint, so I will let it dry for a couple days and go back with a clear coat over top of that.

Cleaned up the speedo drive too, it was not "clocked" correctly on the rim, so no way to attach the speedo cable (probably why there wasn't a cable on it).
Gave it a good coat of VHT Wrinkle-plus. I love the hard finish it makes once it dries out.
(http://i51.photobucket.com/albums/f377/fastcoasty/Bikes/WP_20150826_005_zpstczyjpmf.jpg)

Fixed the chip missing from the front of the fender, welded up some cracks, and primed it out.
(http://i51.photobucket.com/albums/f377/fastcoasty/Bikes/WP_20150826_002_zpsjptmee5s.jpg)
Sure looks better without that chip!
(http://i51.photobucket.com/albums/f377/fastcoasty/Bikes/WP_20150826_001_zpsxxextmic.jpg)

As long as I was at it, I polished the fork brace/fender mount a bit and threw a spot of clear on it so it might last a few days.
(http://i51.photobucket.com/albums/f377/fastcoasty/Bikes/WP_20150826_004_zpstq3gtcao.jpg)

Now I am working on the controls and the levers. They are kind of a mess, and one of the clip-ons is bent.
Trying to see if I can convert over to risers and a regular 7/8" handlebar.
Title: Re: 1984 Yamaha FJ 600- Rise of "The Mighty Jig"
Post by: Matt Rain on Aug 28, 2015, 20:05:16
Nicely done. I'm envious of your shiny bits.  ;D My bike badly needs a thorough cleaning and a fresh coat of paint.

I really like the "graphite" wheels. Maybe I'd re-paint the inside part of the spokes in black to add some contrast, but they already look really sharp.

 8)
Title: Re: 1984 Yamaha FJ 600- Rise of "The Mighty Jig"
Post by: DreadRock on Aug 28, 2015, 22:41:40
Nice looking FJ !
Title: Re: 1984 Yamaha FJ 600- Rise of "The Mighty Jig"
Post by: Big Chuck on Sep 03, 2015, 00:45:39
Had a nice box show up from Ebay today!
Got a new side cover ... with all it's tabs intact! And a chin scoop made out of Un-ubtainium!
(http://i51.photobucket.com/albums/f377/fastcoasty/Bikes/WP_20150902_001_zpss7xti9d3.jpg)

Machined the top tree down last night, now ready to fit a set of risers to it.
(http://i51.photobucket.com/albums/f377/fastcoasty/Bikes/WP_20150902_002_zpsqb7vgdlo.jpg)

Title: Re: 1984 Yamaha FJ 600- Rise of "The Mighty Jig"
Post by: DreadRock on Sep 03, 2015, 10:34:17
Might want to check out ... FJowners..com good group of guys like here and lot of FJ fun parts . I have a 85 1100 I ride every day to work and will never leave my ownership LOL
Title: Re: 1984 Yamaha FJ 600- Rise of "The Mighty Jig"
Post by: Big Chuck on Sep 03, 2015, 19:34:16
Quote
Might want to check out ... FJowners..com good group of guys like here and lot of FJ fun parts . I have a 85 1100 I ride every day to work and will never leave my ownership LOL

Thanks! Your 1100 is very nice... the kind of thing I was looking for when I found this 600.
I had an '85 1100 many years ago, but it was in very bad shape, and I was not capable of the restoration it needed at the time. I will always miss that bike.
There will be another one out there as soon as I get done with this little one! Just have to think of it as practice!
Title: Re: 1984 Yamaha FJ 600- Rise of "The Mighty Jig"
Post by: Big Chuck on Sep 04, 2015, 00:39:22
It's starting to look like Christmas around here with all the parts hanging like ornaments everywhere!
(http://i51.photobucket.com/albums/f377/fastcoasty/Bikes/WP_20150903_002_zpstgk356ll.jpg)

Hard to see, but I managed to get some 2K clear on the forks...
(http://i51.photobucket.com/albums/f377/fastcoasty/Bikes/WP_20150903_001_zpshq18vaxu.jpg)

Took the gauges apart during some rain, polished the lenses some.
(http://i51.photobucket.com/albums/f377/fastcoasty/Bikes/WP_20150902_009_zps8epq4obn.jpg)
Don't look too bad.
(http://i51.photobucket.com/albums/f377/fastcoasty/Bikes/WP_20150903_003_zpsnhibhiew.jpg)

Title: Re: 1984 Yamaha FJ 600- Rise of "The Mighty Jig"
Post by: Big Chuck on Sep 07, 2015, 22:28:27
Just a little bit more ...
(http://i51.photobucket.com/albums/f377/fastcoasty/Bikes/WP_20150907_001_zpsiy57wdng.jpg)

Had to prime some cabinets the boss lady says we HAVE to have in the kitchen (Who needs new cabinets?, if she would let me tear down the house and build a garage with an apartment over it, I could see it - maybe  :D), so I busted out a few pieces of the bike and got to sanding while the gun was full of self etching primer!
Title: Re: 1984 Yamaha FJ 600- Rise of "The Mighty Jig"
Post by: Big Chuck on Sep 22, 2015, 01:01:11
Not a lot of movement on the bike lately, kitchen job turned out to be a disaster!
Did get some rotors in, waiting on caliper kits now.

Managed to spend a little time hamming it up on the mill at work ... made a couple of risers to mount a regular handlebar.

Started with drilling into a couple chunks of aluminum...
(http://i51.photobucket.com/albums/f377/fastcoasty/Bikes/WP_20150917_001_zpsrgaxiyyt.jpg)

Ended up with some rather "Hefty" risers that look like this...
(http://i51.photobucket.com/albums/f377/fastcoasty/Bikes/WP_20150921_001_zpsi6lijclj.jpg)

They are clearanced to sit on the tripple tree top I milled flat spots onto...
(http://i51.photobucket.com/albums/f377/fastcoasty/Bikes/WP_20150921_005_zpsjmkbl8fx.jpg)

They are a bit on the chunky side, but they should hold up!
Need to rough them up in the blast cabinet and paint them black to match the tree top.
Title: Re: 1984 Yamaha FJ 600- Rise of "The Mighty Jig"
Post by: canyoncarver on Sep 22, 2015, 13:52:08
Cool way to continue the thread.  Nice work!
Title: Re: 1984 Yamaha FJ 600- Rise of "The Mighty Jig"
Post by: Matt Rain on Sep 22, 2015, 14:01:22
Why do you want to switch to a handlebar?
Title: Re: 1984 Yamaha FJ 600- Rise of "The Mighty Jig"
Post by: Big Chuck on Sep 23, 2015, 02:11:50
Quote
Why do you want to switch to a handlebar?

Because one clip on was bent, the other one was cut off short, I had the bar laying around (I think it came with the extra stuff with the bike?) because the bar matches the height and pull back of the clip on's real close (is that what you call them?), because I can change it up any time later if I like ...

And because I'm a cheap bastard.
Title: Re: 1984 Yamaha FJ 600- Rise of "The Mighty Jig"
Post by: Big Chuck on Sep 27, 2015, 22:19:16
Made a tiny bit more progress...

Tire and fender are back on, so she sits on her own without a jack!
(http://i51.photobucket.com/albums/f377/fastcoasty/Bikes/WP_20150927_001_zpscczvhpey.jpg)

New rotors look good ... just need to finish up the calipers and hoses.
(http://i51.photobucket.com/albums/f377/fastcoasty/Bikes/WP_20150927_002_zpsk6wpcbco.jpg)

Turned some bar end weights on the lathe, should look a lot like the factory ends sticking out of the grips.
(http://i51.photobucket.com/albums/f377/fastcoasty/Bikes/WP_20150926_002_zps55atftjj.jpg)

Now I am waiting on primer and paint to dry so I can start mounting the new bar.
Title: Re: 1984 Yamaha FJ 600- Rise of "The Mighty Jig"
Post by: veritas.archangel on Oct 15, 2015, 14:46:18
Very cool write up. I have an 85 FJ600 that I picked up for $500 about 17 years ago. Rode it a while, but it has been sitting for probably 14 years. Looking at putting it on a lift and starting a cafe project. Love seeing what is being done with this one, and it gives me hope that I can get my old beast bake on the road.
Title: Re: 1984 Yamaha FJ 600- Rise of "The Mighty Jig"
Post by: Big Chuck on Oct 18, 2015, 22:52:21
Very cool write up. I have an 85 FJ600 that I picked up for $500 about 17 years ago. Rode it a while, but it has been sitting for probably 14 years. Looking at putting it on a lift and starting a cafe project. Love seeing what is being done with this one, and it gives me hope that I can get my old beast bake on the road.

Thanks!
Wish I had a little more progress to report, but I have stalled out with needing a trip to ACE Hardware for metric SS bolts to put it together.
Our local ACE has the best assortment  of Stainless hardware, even metric stuff. I was a bit astounded by the fact they had a large assortment of chrome bolts and hardware! Very pretty stuff! The Harley guys would pass out if they saw it!

Mostly the house has gotten in the way lately.
A previous owner added a deck, and bolted it through the banner board and framing, widened the back door to a double french door (and did not know what he was doing) and later added a roof over the deck .... and guess what? He bolted it to the house through the siding above the door!

Lots of rot...
(http://i51.photobucket.com/albums/f377/fastcoasty/Stuff/WP_20150919_004_zpsnkaktkcv.jpg)

Had to pull the door, remove first four feet of floor in the kitchen, replace 10 floor joists, and rebuild half the back wall.
"Storage" closet on the back was sagging too, as they had destroyed its supports to add the deck, and door had been installed a bit crooked.
(http://i51.photobucket.com/albums/f377/fastcoasty/Stuff/WP_20150919_001_zpsay2tfi8f.jpg)

It's all finished now, but it was a mess.
Wife had to live with a back wall of "house wrap" for a few days until my friend (who made the mistake of admitting he used to build houses) could come by and help replace it all.
(http://i51.photobucket.com/albums/f377/fastcoasty/Stuff/WP_20150920_001_zps7fwjpyz3.jpg)

At least now the boss lady is happy again....at least until she decides on a new floor to put down in the kitchen, then its back to work.
Title: Re: 1984 Yamaha FJ 600- Rise of "The Mighty Jig"
Post by: Big Chuck on Oct 30, 2015, 05:19:12
Not a lot of movement on this ...
Still in the middle of replacing the siding and windows on the house before winter sets in.
The boss lady said it was more important than the bikes!  :o

Finally found some stainless hardware and mounted the risers and the super bike handle bar...
(http://i51.photobucket.com/albums/f377/fastcoasty/Bikes/WP_20151029_001_zpskllv5fc0.jpg)


Not the best picture, and it looks too wide without any controls or anything on it, but I just LOVE the positioning!
Its not as turned down or pulled in as the factory bolt on things. Still clears the windscreen nicely and makes for a comfortable riding position.
Title: Re: 1984 Yamaha FJ 600- Rise of "The Mighty Jig"
Post by: Big Chuck on Dec 26, 2015, 08:42:28
Its been too long since I posted any progress...

Its slow going, one part at a time.
Received new turn signals in the mail, had to modify the mounts on the bike to fit them.
I like the look of them, they look like factory pieces, but are not as huge as the old ones.
(http://i51.photobucket.com/albums/f377/fastcoasty/Bikes/WP_20151215_003_zps8a7jteia.jpg)

Mounted up they look really good.
(http://i51.photobucket.com/albums/f377/fastcoasty/Bikes/WP_20151225_003_zpsn2ogqtfr.jpg)

Front ones will mount up too, but I have the fairing and its frame off for repair.
Cut up an extra fairing to get a replacement piece for the best of the two...
(http://i51.photobucket.com/albums/f377/fastcoasty/Bikes/WP_20151225_001_zpskkulpavm.jpg)
(http://i51.photobucket.com/albums/f377/fastcoasty/Bikes/WP_20151225_002_zpsb3f2yrtl.jpg)

Fitting new levers and cables, working on the dents in the tank, some other things too.
Its killing me not to pull it completely apart and do everything at once, but I told myself I would keep this project together and running as long as possible, try to get all the mechanical, electrical and whatnot done before I disassemble it for paint and powder-coating.
Too many projects (and a few of mine) have never been finished because they became to big a job too fast. Don't want that to happen to this one.
Title: Re: 1984 Yamaha FJ 600- Rise of "The Mighty Jig"
Post by: veritas.archangel on Dec 31, 2015, 20:20:11
Keep up the good work. I had hoped to get my shop done this past summer to I could tackle my '85. As it sits there is a ton of junk, no decent floors, wiring, or bench space. There's barely room to park my Harley, let alone a project that will need a complete tear-down.
Title: Re: 1984 Yamaha FJ 600- Rise of "The Mighty Jig"
Post by: Big Chuck on Mar 27, 2016, 10:13:00
Getting busy again after the winter!

Had a new seat cover made and installed...
(http://i51.photobucket.com/albums/f377/fastcoasty/Bikes/20160321_182944_zpsejbtxs8g.jpg)

$37 for materials, $50 for an hour labor.
(http://i51.photobucket.com/albums/f377/fastcoasty/Bikes/20160321_183246_zpsrfqhucw4.jpg)

Controls going back on the new bars... all the buttons work again, still fires right up!
(http://i51.photobucket.com/albums/f377/fastcoasty/Bikes/20160321_183305_zpsv9skobrh.jpg)

Fairing repairs are just about finished, then I will mount that and route my cables where I want them.
Need to get the brakes back on the front, the dash remounted, re-wire the mess of the coil wires... and take it for another spin!
Plan is to get the swingarm and rear wheel off and restored soon, with all new bearings and chain (maybe do something with the rear shock) and bead blast the exhaust for some new eastwood coating.
I would like to get it together, with all the bits in primer, everything that moves on the front and rear done, the exhaust done, and basically tagged and rideable this summer.
Next winter it can come back apart to clean up the wiring, refinish the engine, and have the frame and whatnot painted (or powder-coated).
We'll see how it goes.
Title: Re: 1984 Yamaha FJ 600- Rise of "The Mighty Jig"
Post by: Big Chuck on Apr 04, 2016, 21:10:06
Had the tank off to empty it out and work on taking the small dents out of it, so I decided to replace the old plug wires made from yellow Accel Super Stock wires (and a lot of electrical tape!), so... I replaced them with some brand new Super Stock wires!
But hey, they were free, just laying around the shed.
Afterwards, hit the starter to see if I screwed anything up ... still runs sweet!
(http://i51.photobucket.com/albums/f377/fastcoasty/th_Bike001_zps0upsbjji.mp4) (http://i51.photobucket.com/albums/f377/fastcoasty/Bike001_zps0upsbjji.mp4)
http://vid51.photobucket.com/albums/f377/fastcoasty/Bike001_zps0upsbjji.mp4

Wondering if I should go ahead and run it out of fuel?


Title: Re: 1984 Yamaha FJ 600- Rise of "The Mighty Jig"
Post by: Big Chuck on Apr 05, 2016, 21:16:08
Pulled the tank apart to start working on it, and decided to rebuild the petcock today.
But... it looks like there is something missing...
(http://i51.photobucket.com/albums/f377/fastcoasty/Bikes/20160405_130642_zps9krzzztw.jpg)

No tubes or filters at all? Full fuel flow from the bottom in all positions? And no filter after this either?
I think its time for a new petcock.
Title: Re: 1984 Yamaha FJ 600- Rise of "The Mighty Jig"
Post by: Matt Rain on Apr 05, 2016, 21:28:27
Mine was missing the reserve straw when I pulled it... ended up replacing it with a brand new manual petcock so I could get rid of the vacuum lines. No regrets.
Title: Re: 1984 Yamaha FJ 600- Rise of "The Mighty Jig"
Post by: Big Chuck on Apr 06, 2016, 08:43:37
Yep... time for one of these...
http://www.ebay.com/itm/Fuel-Valve-Petcock-ASSEMBLY-FOR-YAMAHA-PW80-XT125-XT250-XT350-TW200-TTR90-E-/181856794577?fits=Make%3AYamaha&hash=item2a578277d1:g:XHwAAOSwys5WU2vl&vxp=mtr

Title: Re: 1984 Yamaha FJ 600- Rise of "The Mighty Jig"
Post by: Big Chuck on Apr 20, 2016, 13:37:59
Someone please tell me no... no no no...  :o

Got this Bandit the other day, just about free, for parts or whatever.
Motor locked up tighter than Dick's hat band...
(http://i51.photobucket.com/albums/f377/fastcoasty/Bikes/20160413_1854531_zps5ixlab4m.jpg)

Was looking at it very hard, trying to see how hard it would be to get it's 17" wheels and whatnot onto the FJ...
And I couldn't help but think... would it be easier to mount the FJ engine in the Bandit frame?
Answer? Yes, it probably would be.

So, I was playing around with the FJ fairing sitting on the front of the Suzuki...
(http://i51.photobucket.com/albums/f377/fastcoasty/Stuff/20160418_195307_zpsftdbuzmy.jpg)

Doesn't really look that bad... positioned just right it might work pretty good...

Am I losing it, or is this how these things get started?
Title: Re: 1984 Yamaha FJ 600- Rise of "The Mighty Jig"
Post by: Kamn on Apr 20, 2016, 14:13:15
you are not loosing it ma man....this is how the problem starts BUT to be honest I think you are onto something with this, the fairing actually looks pretty good on there and with the a paint job I bet it would look like this is the way it came

Make it happen
Title: Re: 1984 Yamaha FJ 600- Rise of "The Mighty Jig"
Post by: Big Chuck on May 11, 2016, 21:23:03
Took me a while to get all the angles right, but managed to hold the fairing still long enough to weld a  new piece to hold the fairing bracket.
(http://i51.photobucket.com/albums/f377/fastcoasty/Bikes/20160504_105452_zpseiunawhu.jpg)

Fairing mounted up... most of the old Zuki bits off...
(http://i51.photobucket.com/albums/f377/fastcoasty/Bikes/20160511_095900_zpsti0ryehw.jpg)

With the headlight bucket at the correct angle for proper bulb adjustment the fairing lines up with the lines of the bike and the frame very nicely...
(http://i51.photobucket.com/albums/f377/fastcoasty/Bikes/20160511_095910_zpsauoddxut.jpg)
Title: Re: 1984 Yamaha FJ 600- Rise of "The Mighty Jig"
Post by: hillsy on May 11, 2016, 21:34:14
Looks to be sitting a bit high?


Kinda reminds me of.....


(https://nyhekelambert.files.wordpress.com/2012/03/bike31.jpg)
Title: Re: 1984 Yamaha FJ 600- Rise of "The Mighty Jig"
Post by: Matt Rain on May 11, 2016, 21:37:48
IMO it would look better as a naked bike, with a round headlight.
Title: Re: 1984 Yamaha FJ 600- Rise of "The Mighty Jig"
Post by: hillsy on May 11, 2016, 22:39:48
I like the fairing - its just sitting too high.


The front lower of the fairing should be lined up with the bottom triple - right now it's about 3-4 inches too high.
Title: Re: 1984 Yamaha FJ 600- Rise of "The Mighty Jig"
Post by: Big Chuck on May 11, 2016, 23:46:01
I like the fairing - its just sitting too high.


The front lower of the fairing should be lined up with the bottom triple - right now it's about 3-4 inches too high.

You are right sir... I see it now. I need to drop it down quite a bit.
Thanks for pointing it out.

Title: Re: 1984 Yamaha FJ 600- Rise of "The Mighty Jig"
Post by: hillsy on May 11, 2016, 23:55:27
Don't know what happened with my previous post - the first line somehow ended up being miniature sized font....


Anyway - with the fairing lower you might need different bars to clear it. Such is the world of customizing  8)
Title: Re: 1984 Yamaha FJ 600- Rise of "The Mighty Jig"
Post by: Big Chuck on May 13, 2016, 09:51:11
Coming down...

(http://i51.photobucket.com/albums/f377/fastcoasty/Bikes/20160513_083140_zpsjk6ea7he.jpg)

Have one more adjustment that should bring it one more inch lower...
Title: Re: 1984 Yamaha FJ 600- Rise of "The Mighty Jig"
Post by: Big Chuck on May 16, 2016, 08:51:09
All right... this is about as low as it's going to go without re-writing the whole book.

(http://i51.photobucket.com/albums/f377/fastcoasty/Bikes/20160515_102741_zpskmlfpltf.jpg)

and yes, I may have to use lower bars. I have several to choose from...
Title: Re: 1984 Yamaha FJ 600- Rise of "The Mighty Jig"
Post by: Big Chuck on May 02, 2017, 06:35:06
Ok, time for a reset and a new start...

Original frame, Yami stem pressed and welded into Zuki lower tree, complete forks/wheel/(and eventually brakes) from Zuki.
Rear frame widened about 2mm and pivot bolt holes enlarged to Zuki size with complete Zuki rear swingarm/wheel/etc.

(http://i51.photobucket.com/albums/f377/fastcoasty/Bikes/20170501_190742_zpswg6ejj5i.jpg)

Fork tubes will be a bit high out of the top of the trees to get the ride height correct, but that solves another problem, as clip-on bars would end up just about where the original bolt-on ones would have been.

(http://i51.photobucket.com/albums/f377/fastcoasty/Bikes/20170501_193329_zpsgpuxjlzt.jpg)
Title: Re: 1984 Yamaha FJ 600- Rise of "The Mighty Jig"
Post by: Big Chuck on May 18, 2017, 01:06:06

Finally!
Some simple but sturdy mounts for the Bandit shock and lower joint, then countless scrubbings with degreaser and soap and metal prep and and and ...

 Primer is on!
(http://i51.photobucket.com/albums/f377/fastcoasty/Bikes/20170517_205306_zpsb59hwo5b_edit_1495069543502_zps5jqyhohy.jpg)

Lost count of the sanding and spraying to get it half way ready for a coat of paint.
I really hate tubular stuff.

Another nice day and paint will go on... then its time to get busy!
Title: Re: 1984 Yamaha FJ 600- Rise of "The Mighty Jig"
Post by: Big Chuck on May 22, 2017, 05:13:25
Gotta love painting tubes!
(http://i51.photobucket.com/albums/f377/fastcoasty/Bikes/20170518_195354_zps2gg6mbzv.jpg)

Now to finish painting the forks and the swingarm...
Title: Re: 1984 Yamaha FJ 600- Rise of "The Mighty Jig"
Post by: Big Chuck on Aug 09, 2017, 05:43:06
Well... photobucket!
Snit! Snit! Snit!

I will have to replace as many pics as I can...

Here's the bike right now, going back together.
Bandit forks, swingarm, wheels...

http://[url=https://flic.kr/p/WjkBVn](https://farm5.staticflickr.com/4380/35650790363_12681e119a_o.jpg)](http://[url=https://flic.kr/p/WjkBVn][img]https://farm5.staticflickr.com/4380/35650790363_12681e119a_o.jpg) (http://[img)20621276_130525684227924_715545383929416829_n (https://flic.kr/p/WjkBVn) by Charles Brooks (https://www.flickr.com/photos/152801905@N06/), on Flickr[/img][/url]