'84 FJ600 build

[Patmanbbe]

Greetings all!

I just picked up a 1984 Yamaha FJ600 and will be rebuilding it from the frame up. I got a killer deal on the bike and will be working on a limited budget. The engine will need to be completely gone through as it was sitting in an open garage with no carbs on or any exhaust on it. It will need new sprockets and chain as well.

I also plan to rewire the bike and relocate a few things here and there such as the ignition, tail lights, battery, fuse box, etc. I will need new hand controls as those are M.I.A. The foot controls and passenger pegs. are also missing as well as the ignition and the speedo cluster is junk.

This is my second bike build up. I just finished and sold a 1982 Virago XV920. Loved that bike but I was done with it and wanted a new project to start the new year!

If anyone can help me out with a hi-res wiring diagram that would be awesome.

I will be stripping the bike down this weekend and cleaning and taking stock of exactly what shape the bike is in. Thanks and I will post pics as soon as I can.

 

[rundown]

Excellent, do you have any pictures of the XV?

 

[Patmanbbe]

Small update... I was going to part this bike out but I cant do it. I have never rebuilt a bike from the ground up like this and I want the satisfaction of taking this junker to a runner! I sort of fell like I am rescuing this one as it seems that there aren't very many out there anymore.

I have stripped the bike down to the frame. Engine is still in the frame and I have an intact airbox in the frame as well. I got the chain hooked back up and I was able to turn the motor over a couple time by putting it in 6th gear and rotating the back tire. Glad the engine is not seized!

I pulled the carbs completely apart and am soaking them in carb cleaner dip today. I don't have the gasket kits or new float needles yet to re-assemble so I am waiting on those to come in. I am also rebuilding the stock starter motor and will be cleaning, repairing and getting that back together. I hope to repair and use the stock starter as I had bad luck with aftermarket starters self destructing internally.

I also need to find and purchase a complete exhaust from header to muffler, Rectifier/Regulator, CDI, coils and get a new battery in it.

 

[DreadRock]

Got to love FJs got any pics of what your starting with ?

 

[Patmanbbe]

Got a few pics on my phone of when I brought it home... Lemme see if I can post them up

 

[Patmanbbe]

Here is a pic of it as it sits now in my garage

 

[Patmanbbe]

I will be digging into the bike a bit tomorrow. I am going to get the oil pan on. I have a few stripped bolts that I need to repair but I think for now I will just helicoil them. I also plan to do a compression test and check the valves and adjust if necessary.

I have ordered the gasket kit for my carbs and new float needles. It should be here any day now. I will be finishing the carbs and reassembling them as soon as that gets in. I ordered a new petcock that will be here soon. I went with a manual petcock for simplicity. I also need fuel line plus a fuel filter.

I bought a CDI and R/R from a running FJ600 on Ebay so hopefully those pan out. I also purchase some wire from a member here and will be prepping to wire the bike up. I am hoping my coils are still good if not I will buy a pair of new coils. I also have a rebuild kit for my starter motor so I need to go through that. Need to pick up some spark plugs too.

I plan to build a battery using A123 cells tho I haven't ordered those yet still researching and collecting a shopping list. I am going to order enough to build two 6 cell batteries. This way if I have to I can make it an 8 cell or I can keep the other batter as a spare for another project. I have a leftover battery for now that I will use to wire up the bike and test all my circuits.

I have to get a new throttle tube and throttle cable as the ones on the bike are shot. I picked up a new motion pro clutch cable. I am going to get these on the bike and installed with the stock levers for now. I need a push button kill switch as I plan to use a 3 stage ignition to activate the starter.

I will post some pics up as work on the bike more tomorrow. I want to keep coming back and reporting my progress so I don't drag my feet. If I am reporting in and saying I am going to do something it will help motivate me to get it done! Tired of being without a bike! Thanks guys for being a sounding board and for helping motivate me. Till next time!

 

[DreadRock]

When I did my build I thru as many pics as I could on my thread and just about every lil thing I did . That way if I needed I could go back and see how I did things just In case I forget which happens alot seems like LOL keep up the good work !

 

[Patmanbbe]

I did not get as much done as I had hoped. My paycheck did not hit the bank so I ad to wait on some of the stuff. I also failed to take any pics of what I did get done. Sorry guys.

I did get my starter motor rebuilt and tested and functioning great! I had to patch a pretty big hole in the end cap that covers the brushes with some epoxy putty I will shave and trim it down to look as natural as possible but I was able to match the inside castings without to much problem. Saved me having to buy a new one at over $100.

I also got my carbs fully rebuilt and reassembled and ready to go on the bike.

I am going to stop by a motorbike junk yard this week and try and get some hand control switches, rearsets and levers.

I still need to check my valves and cylinder compression, repair the wires on my Ignition coils as one got ripped out. I need spark plugs and plug wires. Then I can wire up the charging system and ignition system and I will be ready to try and fire up the bike.

 

[Patmanbbe]

Well I have a small update. I found two bolt holes completely destroyed on the underside of the engine case where the oil pan bolts on. I am pulling the motor this weekend and taking to a guy I know who can repair them. A standard helicoil wont fix it as its pretty fuggered up.

 

[Patmanbbe]

Well this weekend I got the engine pulled out and over to a small local shop near Lake Elsinore. He managed to extract and remove broken off bolts and drill bits fromt he badly damaged bolt holes. Then repaired the engine case at a great value to me! Saved me from having to try and source a replacement engine! I can say enough about this guy! If anyone needs a good mechanic in Southern California please let me know. This guy is the man!

 

[bigwill]

subscribed.

Building my own 1984 xj600 and will appreciate your updates.

 

[Patmanbbe]

subscribed.

Building my own 1984 xj600 and will appreciate your updates.

Awesome! I am terrible about remembering to stop and take pictures of what I am doing. I will try to be better about it. Start up a build thread man! I would love to see how it goes for you.

 

[Patmanbbe]

Did some work today. Got the swing arm off the frame and started to de-grease the engine and clean the frame and engine. I cant believe how dirty this thing is.

Right before I removed the rear wheel and swing arm.

Peeling away the layers of grease covering this engine... It is nasty!

I do have a couple of questions.

Anyone have a recommendation for tire brand? It currently has a 130 R17 on the rear and a 110 R18 on the from if I remember correctly.

Anyone have a good method for cleaning out the intake and exhaust ports?

Thanks for the help guys! Time to start picking up more parts and start reassembling the bike.

 

[Patmanbbe]

Well I spent the day yesterday at the DMV and the local Highway Patrol Office. I have an appointment scheduled for a VIN inspection and then the bike will officially be registered in my name. Now that I am sure the bike is not stolen I have ordered some parts. Picked up some fz600 clip-ons and tope triple clamp. A new throttle assembly, fz rear shock, air fiter and oil filter, and some various odds and ends.

I need to head over to Harbor Freight and get some kind of media blaster. I have my uncles compressor at the house so I figured why not. Can anyone make a recommendation on what I should look for. I need to blast the frame, tank and I would like to blast the engine as well as other small brakets and nuts and bolts too. Thanks guys!

 

[Patmanbbe]

Got a ton of parts in the mail this week. I went and picked up some parts from a local guy. Got a great headlight bucket and mounting hardware also got a rear fender and tank from an SR500. I plan to use the SR500 rear fendr to make a mini fender mounted to my swingarm on my rear wheel. Unfortunately the SR500 tank I got from him would not clear the frame. Anyone interested in buying an SR500 tank?

 

[Patmanbbe]

I am sorry I have been so bad about posting pics and updates. I am going out to work on the bike today after work. I will take pics of all the new parts that have come in the mail and some pics of the bike as it sits now. I am hoping to fire it up this weekend after I finish some wiring. Still a lot to do between now and then...

 

[Patmanbbe]

Well it has been a while but I have some progress and some pics to show too.

Stripped the paint off the gas tank. There is a couple dings and gouges I will have smooth out:

Stripping the black paint off the wheels as well. here is a before pic:

Here is an after pic:

I am thinking about just spraying a clear over the wheels as I like the raw color of the metal. I will be painting the tank, stuck between a metal flake green or a metal flake dark blue.

Sorry again guys for the huge delay and no recent updates. Been dealing with family stuff and long work hours. I have also had my hands full welcoming this little guy to the world, we named him Lincoln and he almost made it to us on July 4rth but made us wait till July 7th:

 

[DreadRock]

Hey big congrats man on the lil guy ! When are you picking up his first bike ?

 

[GoCrazy]

Hey, have you done any progress on the build? I'm looking for some inspiration as I'll prpably pick up a FJ 600 myself