DO THE TON

Blood Sweat Tears and Grease => Projects => Specials => Topic started by: interceptor on Apr 20, 2017, 19:24:21

Title: 1984 Yamaha FJ1100 Touring Turd
Post by: interceptor on Apr 20, 2017, 19:24:21
Since I`m a gluten for punishment, I have decided to take on the 1983 FJ1100 and show it who`s boss.    Plans are to first get it back together and running. Everything will be in its stock location, using all stock parts (because I suck at fabricating, plus the bike looks cool).  The only thing I won`t use is the front fairing.  It really has an odd frame, so I`ll have to hide the front a little, but I have some things in mind.  I cleaned up the tank and emptied the 5 year old swamp gas out of there, and cleaned the petcock. Filter looked good, and the tank itself is spotless on the inside. No dents, and paint shined up nice. Does have the key that fits the ignition, tank and seat lock.  I also took a bowl off one of the carbs, and it was spotless. So I may be ahead of the game here!!  Pics to follow
Title: Re: FJ1100 Street Turd
Post by: 540Nova on Apr 20, 2017, 20:10:37
LOL, love the title! That bike could be bad-ass.


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Title: Re: FJ1100 Street Turd
Post by: interceptor on Apr 20, 2017, 22:51:06
Thanks ;D  The inspiration for the front:
(http://i738.photobucket.com/albums/xx25/ssievers/GEDC7125_zpszsqla1m8.jpg)
Title: Re: FJ1100 Street Turd
Post by: 540Nova on Apr 21, 2017, 22:20:09
That's cool.


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Title: Re: FJ1100 Street Turd
Post by: interceptor on Apr 23, 2017, 22:28:28
Today I started piecing this thing back together. I can`t really decribe how rewarding it is for me to do this.  Almost all of the wiring is complete, footpegs, shifter and brake almost all hooked up right now.  I tried putting the carbs on, but dang!!!! I don`t know how I`ll get them in there.  I guess just keep trying.  I`m missing some bolts, so I think I`ll buy a `lot` of bolts on ebay.  Pretty excited to see if I can get this bike started.
Title: Re: FJ1100 Street Turd
Post by: spotty on Apr 23, 2017, 22:39:38
try using a ratchet strap round the front of the engine and the back of the carbs, its worked for me. also lots of lube spray
Title: Re: FJ1100 Street Turd
Post by: hillsy on Apr 23, 2017, 22:55:18
Hit the intake rubbers with a heat gun before you try and mount the carbs. It makes things a whole lot easier.
Title: Re: FJ1100 Street Turd
Post by: interceptor on Apr 24, 2017, 05:45:16
Thanks guys.  I'll give them both a try  :D
Title: Re: FJ1100 Street Turd
Post by: der_nanno on Apr 24, 2017, 05:49:05
A hairdryer/heatgun plus something to lube up the carbs and rubbers (I use WD40 or brakecleaner) and they should go in with ease!
Title: Re: FJ1100 Street Turd
Post by: interceptor on Apr 24, 2017, 05:59:39
A hairdryer/heatgun plus something to lube up the carbs and rubbers (I use WD40 or brakecleaner) and they should go in with ease!
I have access to a heat gun from work.  I'll give it a shot after work :D  Thanks!
Title: Re: FJ1100 Street Turd
Post by: interceptor on Apr 25, 2017, 06:28:55
Does anyone recognize the front windscreen on my inspriational bike?  It seems like it may be from an atv, but I can`t find any pics for confirmation.   
Title: Re: FJ1100 Street Turd
Post by: stroker crazy on Apr 25, 2017, 07:04:48
Could it be a re-purposed belly-pan?

Crazy
Title: Re: FJ1100 Street Turd
Post by: interceptor on Apr 25, 2017, 11:18:46
I never thought of that, but I guess it could be.  I've never really looked straight on at a belly pan. 
Title: Re: FJ1100 Street Turd
Post by: interceptor on May 01, 2017, 15:05:00
New direction!  All stock parts are going back on, and I want to find a corbin seat and luggage for it.  Retro cruiser  ;D
Title: Re: FJ1100 Street Turd
Post by: interceptor on May 02, 2017, 07:15:02
The wiring harness came pretty much hanging from the machine.  I spent this morning trying to place it back in its original location.  It wasn't really too hard, but finding the exact way it once laid was challenging.  I think I'm about 75% there  :D  The only thing I'm missing is the flasher unit (I think).  The throttle is a push-pull and all the parts are there, but I need how to figure out how it lays under the tank.  It's all good, I'm having fun - Any progress is rewarding to me  8)
Title: Re: FJ1100 Street Turd
Post by: interceptor on May 03, 2017, 07:46:14
I got a bunch of stuff figured out this morning. Its cool looking a pictures on the internet, recognizing something, and then running out to the garage to put the parts in place.  Got the carbs mounted last night, ordered a used air box and figured out some more wiring.
Title: Re: FJ1100 Street Turd
Post by: interceptor on May 04, 2017, 11:18:38
This morning, I realized, after looking at a parts diagram on Bike Bandit, I forgot to install the shield behind the carbs. So off came the carbs again, and on goes the shield.  They did seem to go on a little bit better than last time  8)  After that, I tackled the choke cable.  Being the cheap ass I am, I went to the local bicycle store yesterday and bought a stretch of bicycle brake cable.  It already had a piece on one end of the cable, but I had to make something work for the other side.  My buddy Eric gave me a universal end that I used.  The only thing I had to do was drill out a pocket in the barrel and weld a tit on the end of the cable.  It fits into the pocket and should work just fine. For $3, I'm happy  ;)   
Title: Re: FJ1100 Street Turd
Post by: hillsy on May 04, 2017, 20:21:14
This morning, I realized, after looking at a parts diagram on Bike Bandit, I forgot to install the shield behind the carbs. So off came the carbs again, and on goes the shield.  They did seem to go on a little bit better than last time  8)  After that, I tackled the choke cable.  Being the cheap ass I am, I went to the local bicycle store yesterday and bought a stretch of bicycle brake cable.  It already had a piece on one end of the cable, but I had to make something work for the other side.  My buddy Eric gave me a universal end that I used.  The only thing I had to do was drill out a pocket in the barrel and weld a tit on the end of the cable.  It fits into the pocket and should work just fine. For $3, I'm happy  ;)


I hope when you say "weld a tit on the end" you meant solder??


Anyway, bicycle cables are a great resource - I use them all the time. You should get some more and make up new throttle cables to ditch that connector box under the tank. They have been known to seize often.


And it's probably not a bad idea to run a fuel pump like the 1200's do - the fuel line routing for the 1100 is pretty sketchy and they often get vapour lock and other fuel delivery issues (hence why they ran a fuel pump on the 1200).
Title: Re: FJ1100 Street Turd
Post by: interceptor on May 04, 2017, 20:58:01
I tried soldering it, but it wouldnt reveive the solder. I used flux, too. Anywys, i put a magnet to the wire and it was attracted to it, so I put my welder on A and 2 wire feed, and welded a tit on the end. Worked great!  Good to know about the fuel pump. And i will look into the throttle cables.  Thanks ;)  Also found some 20mm ammo boxs` to make my panniers  ;D
Title: Re: FJ1100 Street Turd
Post by: hillsy on May 04, 2017, 22:15:35
Welding the wire will probably not last long - it makes it brittle and will more than likely snap.


You need to make sure the wire and the nib are TOTALLY CLEAN so the solder will flow. I use brake cleaner.
Title: Re: FJ1100 Street Turd
Post by: interceptor on May 05, 2017, 07:12:20
Thanks for that, I will try it.  :)
Title: Re: FJ1100 Street Turd
Post by: interceptor on May 05, 2017, 16:37:31
So, has anyone installed one of these choke cables? Inparticular, how it connects to the choke control that you twist on the left handle bar. 
Title: Re: FJ1100 Street Turd
Post by: interceptor on May 07, 2017, 14:22:01
I figured out the choke cable control  ;D  The new cable I made works great!  I'm glad I took my time installing it, because there was about three things I was doing in the wrong sequence to install this thing.  I also figured out that the throttle cables are sticking, so I will probably take hillsy's advice and make some throttle cables and bypass the throttle cable box.  On top of that, I ripped all the old fabric off the seat, and am thinking of installing a new piece my self.  Wish me luck :D
Title: Re: FJ1100 Street Turd
Post by: hillsy on May 07, 2017, 23:27:43
Are you buying a new seat cover or making one up? They just staple on so that part isn't too hard  ::)
Title: Re: FJ1100 Street Turd
Post by: interceptor on May 08, 2017, 05:42:35
hillsy, I went to a local fabric store last night and bought a remnant piece of UV protected black vinyl.  Good thing is is that it was a remnant piece, so half off.  I also bought some foam adhesive.  I think I have enough fabric to do both this seat, and my ATV seat  8)
On a side note, I took a cable out of the equation in the twist throttle, and now it just pulls. I also greased the inside of the throttle cable box - seems to work just fine now.  I also spent some time this morning working on the front cowl.  I bench tested the light and installed that and the gauge cluster into the cowl.  All in all, it's going back together pretty well.  I'd like to take the valve cover off and check the backlash, but looking into the 1200, they use shims and a special tool.  I need to verify if that's how the 1100 is.  If it is, I may need to forgo that, or have a shop do it. 
Title: Re: FJ1100 Street Turd
Post by: hillsy on May 08, 2017, 09:48:16
1100 and 1200 motors are the same - just a different bore size.


You can still check the clearances without having to have special tools. You might be lucky and not have to change any shims anyway.


Be careful doing up the cam cover bolts - easily stripped if you try and overtighten them.
Title: Re: FJ1100 Street Turd
Post by: interceptor on May 08, 2017, 11:08:39
Ok, good to know, thanks :) 
Title: Re: FJ1100 Street Turd
Post by: interceptor on May 08, 2017, 12:06:22
All done with the seat.  I`m happy with it  :)
Title: Re: FJ1100 Street Turd
Post by: hillsy on May 08, 2017, 21:32:10
Nice work!
Title: Re: FJ1100 Street Turd
Post by: interceptor on May 09, 2017, 05:05:28
Thanks  ;)  I am now looking on ebay for a pivot bolt for the shifter and a chain guard .  Unfortunately, the PO didn't include these items with the bike  :o

Title: Re: FJ1100 Street Turd
Post by: interceptor on May 13, 2017, 06:44:20
Last week, I ordered an airbox off of ebay and finally received it, only to find out that the right side cover was missing.  My fault for not seeing that when I bought it I guess.  So back to ebay - The same seller was selling the cover separately!  Had to buy that, too  :'(  The next steps to getting this bike to start would be to check the valve clearances, plug in some electrical connections, install the carbs and try to start it.  Easy Peasy! I'm sure it'll start right up  ::)  I do have a 4 into 1 exhaust manifold that came with the bike.  I think I'll put that on just for start up.  I'll have to get something else in the future.  The thing is pretty ratty!  And I soaked the chain for 3 days in motor oil and hung it at work.  Looks to be in 'ok' shape.  Nothing I would want to ride cross country, but it'll work to test for the dreaded 2nd gear issue on these things.   
Title: Re: FJ1100 Street Turd
Post by: interceptor on May 13, 2017, 17:44:59
So who is the resident FJ 1100 expert around here?  Question:  There is the big fuel line (2 into 1) coming from the carbs that goes to the petcock and there are 4 overflow lines coming from the carb bowls. These I understand.  Then there is a tube coming from the petcock that I would imagine goes to the engine somewhere (vacuum)? I'm not sure where it hooks up on the engine?  And also, there are two more medium sized tubes coming from the carbs that I have no idea where go.   If it makes sense, great.  If not, I can provide a picture at a later time.  Thanks in advance.
Title: Re: FJ1100 Crusty but Trusty
Post by: hillsy on May 13, 2017, 21:45:28
The vacuum hose goes off #2 intake rubber, IIRC.


The two "other" hoses will be breathers hoses for the carb bowls. Or if the bike is a California model, they might have gone to carbon canisters. Either way, just route some tubing either down in front of the swing arm or up under the seat - don't plug them up.
Title: Re: FJ1100 Crusty but Trusty
Post by: interceptor on May 14, 2017, 13:50:22
Thanks for the info.  I see the spot where it hooks up, but there is a small boot covering the port. On the 3 and 4 carb ports,there is a small tube thats there that connects the two.  It appears they have been there for awhile.  Hmm??  When you say carb number 2, I am taking it as the second carb from the right. 3 and 4 are the two on the left.
Title: Re: FJ1100 Crusty but Trusty
Post by: interceptor on May 14, 2017, 13:51:44
#2 carb?
Title: Re: FJ1100 Crusty but Trusty
Post by: hillsy on May 14, 2017, 23:42:47
cyl # 1 is on the far left when you are sitting on the bike.


It doesn't matter where you plug in the hose for the vacuum tap - any of the ports will work.


From memory, I think the earlier FJ's had a vacuum advance (the hose that's on #2 in your pic). Where does that hose go to?
Title: Re: FJ1100 Crusty but Trusty
Post by: interceptor on May 15, 2017, 06:18:24
It goes to the number 1 carb.
Title: Re: FJ1100 Crusty but Trusty
Post by: hillsy on May 15, 2017, 06:46:59
It goes to the number 1 carb.


OK - have you got the ignitor? From memory that hose went there on the first models. If it doesn't on your ignitor then you can route that hose from #2 to the fuel tap and cap off the port on #1.
Title: Re: FJ1100 Crusty but Trusty
Post by: interceptor on May 15, 2017, 09:13:18
I'm going to say that it does, because you mention early bikes, and this bike has an 1983 VIN Tag on it.  I remember on the igniter there is a small looking tube or handle that comes off of it.  I didn't know what it was for.  I'll look at that when I get home and see if it's an actual tube.   
Title: Re: FJ1100 Crusty but Trusty
Post by: interceptor on May 15, 2017, 22:09:09
Jackpot..... it goes to the igniter.  Thanks :D
Title: Re: FJ1100 Crusty but Trusty
Post by: interceptor on May 17, 2017, 21:59:13
I bought a nice AGM battery and installed it on the bike, crossed my fingers, and turned the key.  The neutral light came on...yes.  Tried the foot brake, and it worked... yes.  Tried the front brake, and the brake light came on...yes.   Hit the horn button, and got nothing.  Darn.  Hit the starter button, and got... nothing.  Hmm?  Oh, I need to have the clutch in. Pulled in the clutch, pressed the starter button, and... nothing.  Hmmm?  Thought about it for a second, and saw the kickstand was down. Ah ha!!!  Put the kick stand up, pulled in the clutch, hit the starter button, and... nothing.  Damn!!  I paused there and thought about it a little. Lets try the lights.  Nothing! Damn!!!!  No running lights and no blinkers.  So either all those work when the bike is on, or I have some serious issues.  First thing is get out the multimeter tomorrow and chase the power from point to point.  I'll also try bypassing the solenoid to see if the starter turns the engine. 
Title: Re: FJ1100 Crusty but Trusty
Post by: hillsy on May 17, 2017, 23:37:51
Yep - all the lights, indicators, etc should work with the ignition on regardless of whether the bike is running or not. Check fuses / power to the fusebox first up.


Also, the horn stopped working on an FJ1200 I had and it ended up being a corroded switch - a quick sand / clean and it came good (although your problems sound different). Worth checking this and the starter button nonetheless.
Title: Re: FJ1100 Crusty but Trusty
Post by: interceptor on May 18, 2017, 05:28:49
I was wishing for the moon, I just hooked everything up, I didn't clean anything and I didn't check anything. But there wasn't anything- buzzing or lights flickering a little, crackling, when I pressed all these buttons.  Not a sound.  My thoughts are that there is a safety switch not working for the starter, and to clean the controls and check the power to the fuses (as you statred).    Good call!  ;)
Title: Re: FJ1100 Crusty but Trusty
Post by: interceptor on May 19, 2017, 05:45:39
Did a little investigation this morning.  Good news is that I have some power to everything.  The bad news is that it's only 8.3V.  I would venture to say that I need to start cleaning the controls and connections to everything.  I understand how to take out the male ends out of the connections and clean them, but how do you guys clean the female ends?   
Title: Re: FJ1100 Crusty but Trusty
Post by: hillsy on May 19, 2017, 10:39:08
If it's that low to everything check the ground from the battery first.
Title: Re: FJ1100 Crusty but Trusty
Post by: interceptor on May 19, 2017, 11:45:13
If it's that low to everything check the ground from the battery first.
Got it.  Thanks :)
Title: Re: FJ1100 Crusty but Trusty
Post by: interceptor on May 20, 2017, 12:49:33
Yay!!  I cleaned the connections for the right side control and the emergency stop switch and starter button both work now  ;D  I used a concoction of vinegar/salt for the cleaning, and then I dipped it in water with baking soda.  Worked really well.  I took the left side control apart and it will require some work, it is really filthy.  I'll have to do that at work on Monday.  I've attempted to install the chain it came with, but it appears to be too short by a link or two.  I'll move the wheel all the way forward and see if that helps at all.  After that I can hook up the return spring on the right foot control.  I have to take the whole bracket off to get to it.  I tried from underneath, but I couldn't do it. 

So by getting the starter to turn the engine, this tells me the solenoid works, the control works, the starter works, the engine is free and the emergency stop button is functioning.  And two of the spark plug wires don't have caps, and was creating a spark to the engine.  So at least those coils appear to be working.  All good in the hood!!!
Title: Re: FJ1100 Crusty but Trusty
Post by: interceptor on May 21, 2017, 17:55:06
I`m happy to report that I did get the chain and the foot brake return spring installed this morning.  I also managed to clean the left control. Everything now works with the exception of the blinkers. I forgot my meter at work, so I`ll have to check voltage and continuity tomorrow.  Also, the front light works with the hi/lo beam operation.   ;D. I ordered new plug boots which should be here soon.  I think while I wait for all that, I`ll change the oil, plugs and oil filter.  I`m looking for reccomendations for oil.  Should I get Yamaha specific, or conventional 15w40?  I have read not to use any additives or synthetics. I understand the synthetic, but not the cleaner additives. Is it because of the clutch plates?
Title: Re: FJ1100 Crusty but Trusty
Post by: hillsy on May 21, 2017, 19:51:01
I`m looking for reccomendations for oil.  Should I get Yamaha specific, or conventional 15w40?  I have read not to use any additives or synthetics. I understand the synthetic, but not the cleaner additives. Is it because of the clutch plates?


Yes - car oils with additives can muck up your clutch. You want to use a motorcycle specific oil, or a diesel oil like Rotella that has no friction modifiers.


If in doubt, get a semi synthetic 4 stroke motorcycle oil - 10w40. There's a bunch of brands out there.
Title: Re: FJ1100 Crusty but Trusty
Post by: interceptor on May 21, 2017, 20:14:49
Ok, thanks. There is a motorcycle dealer on my way home from work.  Easy enough to stop and get some yamaha motor oil:-)
Title: Re: FJ1100 Crusty but Trusty
Post by: interceptor on May 23, 2017, 05:59:54
Last week, I ordered a few things off of ebay.  First was a new air filter.  The one that came with the air box seemed like an aftermarket type, and I really need this to be stock because I don't want to rejet the carbs.  (Not sure I would have had to, but who knows)  I am worried about the exhaust because what came with it was a 4 into 1 pipe.  Hopefully it won't cause too much trouble.  Some other things I ordered were:  a chain guard, rear foot rest-left side, and most important,  a new shifter with the pivot bolt.  I couldn't find that bolt and was going to try and make something, but when I received it in the mail, I'm glad I found one.  The shifter is actually in better condition, and the pivot/mounting bolt is a lot different that I was picturing.  I also cleaned up the front brake reservoir, and installed new crush washers for the hose.  I'll grab some brake fluid and try to fill the front brake system tonight.  While I was at the dealer, I also ordered another banjo bolt and washers for the hydraulic clutch.  I didn't get around to installing the new spark plugs and changing the oil.  I figured I'll do that when I check the valves, because I think I need to take the left cover off to rotate the engine anyways.  On a side note, this bike is frickin heavy!  I've been dealing with CB twins for that last 8 years, and forgot how heavy bikes can be.  My V Star I had was heavy, but this thing is a tank! 
Title: Re: FJ1100 Crusty but Trusty
Post by: interceptor on May 25, 2017, 22:08:59
Here's the funny thing.  Even though I haven't gotten too much done in the last few days, I sit back and think about it, and actually I have.  A couple of cotter pins, tightening some things, adding some bolts.... it all adds up.  I got the piece of crap 4 into 1 header I got with the bike and put it in place.  Two of the down pipes have been re welded.  They actually fit into place, so I'll cut off the cobbled welds and weld it right.  I think with some sanding and paint, it will actually work out.  The only thing I am running into right now is that the outlet is 2.25" (57mm)!  It seems kind of hard finding a slip on muffler that will fit that big of an outlet.  I'm looking for some help with a solution here.  Maybe I could build something?  Or also looking for a cheap muffler if someone has one sitting around that might work.  ebay has a few options, but nothing that I like.
 Thanks in advance :)
Title: Re: FJ1100 Crusty but Trusty
Post by: hillsy on May 26, 2017, 01:05:42
It was a while ago, but I put a car muffler on my ZX9R and I'm pretty sure the inlet was 60mm.


(http://i428.photobucket.com/albums/qq6/hillsythegreat/ZX9During.jpg)


In other words, a lot of 4-1 midpipes had a 60mm exit.
Title: Re: FJ1100 Crusty but Trusty
Post by: interceptor on May 26, 2017, 05:25:52
Hillsy, thanks for the response  ;)  That's pretty cool, I guess I would never have thought of that.  With exhaust, is it ok to lengthen the whole thing?  I mean to say that the outlet is on the right side, right below my foot.  I'd like to lengthen the mid section to allow the muffler to sit back more. 
Title: Re: FJ1100 Crusty but Trusty
Post by: hillsy on May 26, 2017, 06:16:47
Absolutely. It will probably run pretty bad if it ends near the foot pegs anyway.
Title: Re: FJ1100 Crusty but Trusty
Post by: interceptor on May 26, 2017, 07:07:49
Perfect.  Thanks :)
Title: Re: FJ1100 Crusty but Trusty
Post by: interceptor on May 28, 2017, 11:12:46
Today is a big day for me.  I received the spark plug boots I've been waiting for yesterday!!  I took some time to install the spark plugs a few days ago, installed the new spark plug boots (NGK), installed two new rear brake/running light bulbs (working now), and installed the 4 into header.  It turns over and has spark.  I'm going to attempt to start it today.  If all goes well, I'll be reporting good news later  :D
Title: Re: FJ1100 Crusty but Trusty
Post by: interceptor on May 28, 2017, 17:05:08
Started right up on starter spray  ;D
Title: Re: FJ1100 Crusty but Trusty
Post by: interceptor on May 29, 2017, 21:44:46
I installed the fuel tank this afternoon, plugged everything in, put some fuel in the tank, crossed my fingers I wouldn`t see any leaks. After watching for a good five minutes, I felt good to go.  Turned the key to on, twisted the choke, hit the starter button and..... vrroooommmm!!  Its alive!  Sounds pretty good with the open exhaust, too .  All four pipes were getting hot and when i reved it up, no stumbles and returned to idle quickly.  Pretty damn sweet. On a side note,  I did order a muffler that will be here later this week.  All I have to do now is bleed the brakes and the clutch and I`ll see how it does on the road.
Title: Re: 1984 Yamaha FJ1100 Touring Turd
Post by: interceptor on Jun 02, 2017, 11:50:52
Here are the beautiful welds I`m going to grind off and redo :-)
Title: Re: 1984 Yamaha FJ1100 Touring Turd
Post by: spotty on Jun 05, 2017, 23:47:16
Here are the beautiful welds I`m going to grind off and redo :-)

I've seen worse....I've done worse for that matter

is that pile of coathangers your supply of filler rods for oxy welding?  does work in a pinch (or period of poverty for that matter)
Title: Re: 1984 Yamaha FJ1100 Touring Turd
Post by: interceptor on Jun 06, 2017, 05:26:16
I'm not quite sure what it is?  All I know is that it was close to an inch thick, and still had pin holes and you could hear the exhaust popping through.  I did grind off a small section just to see what was going on underneath that mountain of steel and it literally took me 2 minutes to weld it and grind the small section I did. What I did find is that it was cracked all the way around.  I'm pretty sure he hit something with the exhaust, because the bottom pipe is beat up and the pipes are bent.  May try to save this thing in the future, but for now I just put it on and called it a day. The bike sounds good with the new muffler I got, too   :D
Title: Re: 1984 Yamaha FJ1100 Touring Turd
Post by: interceptor on Jun 06, 2017, 22:24:33
Thanks everyone for your posts.  I've decided to put the bike in hibernation for the next 10 years.  Till then, I'll collect some parts to rebuild/restore it when I semi-retire.  Thanks again  :)