Commuters Motorcycle Club

Your bike, your style! - Tell us about you and your bike in here! => Blog it! => Topic started by: Rob the Nog on 14:59 - 4 February, 2019

Title: Nogs FJ Restoration Project
Post by: Rob the Nog on 14:59 - 4 February, 2019
So I finally found a bike I like the look of, in need of some fettling and getting back into a reasonable state, and here she is:

(https://i.imgur.com/P1SdKWT.jpg?1)

A 1986 FJ1200

Looks a lot better in this picture so here's a few more to show the general state.  Basically it's got a very long and hidden past (no history at all came with it) and the mileage is approximate as it was over 97k miles when the clocks were changed, but if the MOT's are anything to go by it's just shy of 100k.  Before I put the wonga down the guy sent me a video of it running etc as I couldn't view in person but was happy it wasn't burning oil and at the price I was getting for it was definitely worth a punt.

(https://i.imgur.com/JIyfyCW.jpg?1)

(https://i.imgur.com/1Tb8HyV.jpg?1)

(https://i.imgur.com/c8WDWsN.jpg?1)

(https://i.imgur.com/WNeSgNd.jpg?1)

(https://i.imgur.com/QBNx8aY.jpg?1)

So arranged for a bike delivery guy to drop it off this morning and tried it out to see what I'm looking at - fired up on the button which was a good start, tick over is too low and a touch rough, but when I smelt the fuel in the tank it's obviously very old fuel and probably isn't allowing it to run at it's best.

Either way, it'll now get a full strip down, new fluids, carb service, brake service etc etc.

The plastics are in a bit of a state - I reckon it's been on it's side at least a couple of times and as you can see the tank is the wrong colour so has obviously been replaced.  I'll be repairing the plastics as best as I can and respraying all the front plastics and tank back to a nice black - I checked on ebay and decals are available so if I make an ok job of it I can hopefully have it looking fairly stock again - but that side of thing is a good way off yet.
Title: Re: Nogs Resto Project
Post by: Rob the Nog on 12:24 - 5 February, 2019
Have spent a quick bit of time in the garage just getting it stripped down so I can see what lurks underneath.

(https://i.imgur.com/vpeSL9F.jpg?1)

Front end all looks straight which is good - left grip was loose but I have some spares from the TDM when I put the heated grips on, so took it off and will be putting the others on anyway, easy first job :)

Frame has a lot of surface corrosion, but going over it all and it seems nice and solid, will be getting stripped back and repainted.

(https://i.imgur.com/qSTP7TI.jpg?1)

Engine sounds good as mentioned and doesn't burn oil, but the valve cover is in need of a strip and paint.  It'll be getting a full clearance check anyway so the cover will be stripped and painted while I'm doing that anyway.

Carbs will be cleaned out and new air filter etc going in.

Inside the petrol tank looked ok but a fair bit of surface rust here and there. Will be giving that a bit of clean with the old nut and bolt method to scrub off the surface rust and clean it out before repainting.

All in all I'm pretty pleased with it.  It's no looker at the moment but it's a big old lump and I'm hoping will come up nice.  I paid a price I was happy with, which I could get back just selling the engine and headlight alone, so I'm hoping when it's all done I should at least be able to cover the cost of the things I need to get up to scratch but that's not really why I got it, more just a project for the year and maybe might keep a little while and enjoy it myself if I like it :)

I'll prune the blog back now and again just to keep this as a diary of what I've done to it so I can keep track of the work easily, so don't be offended if you see a post disappear after a couple of weeks, nothing personal - you're still free to take the piss as usual  ;)
Title: Nogs FJ Restoration Project
Post by: AlunL on 15:27 - 5 February, 2019
I’m envious!
Loved my FJ12. Still may get another at some point.
Looking foreword to seeing what you do to it.

(https://uploads.tapatalk-cdn.com/20190205/24e9949643cf087df8aed829a5f8186b.jpg)
Title: Re: Nogs FJ Restoration Project
Post by: Rob the Nog on 09:20 - 7 February, 2019
Have found some XJ900 clocks on ebay that are being sold at a very reasonable price - amazing the range you can find, some people want silly money for things.

Essentially the same clocks, but advertise them as FJ1200 clocks and they are eye wateringly priced.  A set of XJ900 clocks suddenly become nice and cheap.

The speedo doesn't go as high and I think the red line is different, but the graduations are the same, so I can use the faces from my current ones on the XJ clocks and should be fine.  Also has the digital clock, which is nice  :)

Have decided I will drop the engine, might as well do it properly.  Once the weather gets a little better and the ZRX is off the stand, I can drop the engine and then get it up in the air for a good clean up and repaint.  Also can check out the rear shock and swingarm and see if it needs attention (my bet is it will).
Title: Re: Nogs FJ Restoration Project
Post by: Rob the Nog on 08:55 - 11 February, 2019
That bike deserves a full strip down and ground up rebuild nog!
Will the xj1300 engine shoe horn in there ?? 8)

I love the fj in  the blue white and red colours.

Yeah having dug a little deeper it definitely needs a good strip to clean up and get things nice again.  I really like the white and red colour scheme, but I think I'll stick with black and red, although will add much bigger red stripes when I finally get there as the black FJ's look a bit boring.

I took the air box and carbs out and it's pretty horrible undernearh.  Bloody airbox needed top subframe mounts removing, you can see why people move to pod filters.  I'm not sure about that as I don't want to have to mess with carbs, but any running issues and I also don't want to mess around each time I need to get carbs out.  When I finally come to test run it I may leave the air box off and see if the fuelings ok without.  If all running ok from a carb point of view but fueling isn't ideal, I could then put airbox back in with a view to (hopefully) not needing to mess again.

Anyway, a view under the airbox area:

(https://i.imgur.com/LUpTNh1.jpg?1)

The top of the shock frame mounts etc all look a bit grim.  Solid, but in need of a good strip back and repaint at the least.  I'll probably go the full hog and remove the subframe completely and repaint that too, then I can get better access to get the swingarm out and also check if a new shock is needed - it doesn't look too bad, but who knows how many miles that things done.

Also took the valve cover off, cams all look in good nick which is a good sign.  Will do a clearance check just to get that out of the way.

(https://i.imgur.com/19pegKH.jpg?1)

Had a look at the carbs and apart from some rusty gunk in the bowls they don't actually look too bad.  Diaphragms seem ok which is a big one as replacements are big money, cleaned the jets out and will probably leave them alone as the bike seemed to run ok, so apart from an external degrease and clean I think I might take the 'if it aint broke' approach with those.
Title: Re: Nogs FJ Restoration Project
Post by: Rob the Nog on 11:31 - 19 February, 2019
Having been a bit annoyed the Abba skylift didn't have adapters for the FJ, I spotted some Abba swingarm removal adapters which are universal and lock into the footpeg mounts instead.

Should be ideal and also mean I can use for any of the bikes I may have to whip the swingarm off anyway.

Not sure I'd trust having the FJ completely supported up in the air on them, but lifting either the front or rear should be fine but also mainly to lift the bike off the engine so I can get the frame up in the air for cleaning and repainting :)

Just need to get some decent garage time now to get balls deep in it.
Title: Re: Nogs FJ Restoration Project
Post by: Rob the Nog on 15:34 - 23 February, 2019
Now that ZRX is hopefully finished got to work more on the FJ.

Got it up on the Abba stand and started stripping the subframe off.  A bit manky underneath, but all getting a repaint so no big deal, nothing serious to worry about anyway.

(https://lh3.googleusercontent.com/8svVH-AP9bSY3X4zwdGmjk53Sft1X6eAn9xW9fd4phvBnTETeznCydCQT2x1KXAXAaZMf5B430d24cBXJ6mqRCJWeZEj7qAsz-Wgv2atUGuofgZSE3y1LGUf00tSRc8rPtfl3ZQoMayUJGYBXHQWp7EQTYmvsbNiDuXoasicaIr2F3LFCxZ8GczCenPx5Wn6jctJOg9rQYBMCEg_7cnZUV1Ok1h_yTFJFJcYgHmpaGUluCmeQ1VjnmWip5PRcmISpZbWevovATq-sulwswCsKYPdvdx0LbSVdWLTINbfNzR9EIo3EnEYMdtRbca-iyZcZOpWVfzNfotItG0vIyomiEFOQPzWN4a7niKpwn8BcdiHOw37Y33n1n54r2gS94ItWhK19kr524o2ImZaidpsGkzizQw8-MZMKJuxnUfV5z0FC3y-YtZRbndrhtHigLPFkvRIzKnkF3s4rVSbTcCftEpsDk_OfdLvsPWTFOQU1yNFnk9EvsprNaGQrHndMCesH4-wiiiDKbmprQTpRHIQDoXzIxv1TErNyiCM_oMQZXC3ZOe6wdPmFEvIq8L0tiRD3hiKXqJm_7huXrFqIXjo7jUPaW0fNJEI4cNuArB5GGy0BgkVV8ztiHhJCDptn01z4xh_2MdVpNPzJXb3EghB2sHKx_xYRSk=w1709-h961-no)

(https://lh3.googleusercontent.com/IUSm9gcgrM1MNS_SRxuZzsXXbh64bQIwbX8hZrtZnb-em2r6kj3M4OhI5qb4_XgrF14uTGux131TwXGKgTyZrfD0Qgm6F0nk1VVz8oRfIR2YafkVRm5Bl6XjnrPNmYOGOYWs-gjfnfrz6KSCgAN9uS-8sd6P_9QoZXtjiUBRSwYD3_AGK437KbuqhmEP8H3Mm3AYvIpH_Acd31edC4J3E1lGMFFgJOc6uFdSkxzY30Zxmn_qtJnJPPelkF1HMQJvguVcTgPtjJ6hWfBgc2JKc_oQkyW4t87Uon1mAdG8w6VUVNQgDEVx0rQqHDraFuWxi04hlkAe_SdptRTcxsHNESzquWu0TPKKvZCC53RWgkDKV2EB4qYSbIVbxGOPfttAphtshw9gpN6-06c92jZn0mzfapqgxNbza5V6wybTb_mBi4rxRP5C_-sVxt7b3bg21jdC5WCpaIA-3HzZpGGfv036Q4mf47xmeInCTtebERbENSH7dNmwDBqkDRi-Zn5zNANxqN1IBdjFTm4Vw-S4bw3rFwzsX_S_yv3ux-co9bfyhd4gfS32OC908dXWjBr_rLE03qDqCCtvD7X1jnCTcVMjfcrIDLNElcWeNjjIqFETBNLAj97YV2rHJDdUg3AUHPSw6smait2a3QFGdIn0upaGiUMOuDI=w541-h961-no)

Took the rear caliper off and torque arm, some bolts ok, others a bit mullered so will be looking to change some in the rebuild.

With the rear tyre out it's starting to give me some room to get in there.

(https://lh3.googleusercontent.com/s_b2LJ6HVQ9OvnWlefF6t2bvs_1l0HlRo7PozpmZALqOJZUKqY1wOIKs1uDFnA-jiw8Xlamy22UT9tXl1cpKB1l_U3kvHhbXFsarw_mV8K32nxPGbKHrLSKNnMbnz4bIva9qGDYNnaAUmeV4PithhpDdADKdg0ioes9qBznzlM4TZIZo9HaSrCeJufKQad8UVThiTsWuZTAlFohz94b9BJcrg4b3gdv3oYWQGobbSnP1SAsE5PuR7f-hLpzWWN0umEIQNTT4ggWXqqF1tAzDfVKbWRY3yQj3cZmDZMuwQseXesx51y6s-3DSr8f363RjZRhsKWMU_YYe2BW6d9qs64E6wHilr2c9C90bm2bFnWpeWFWUI0Uemr6i2GUJYVAzQ3rpQnPsHrPjyR8-nBofyFfLGq3GCuLru1YtvkjsJSErW9j_U2KKaO540-Fw6itREyxRYMWx2vtNMXMDztNwg6iLvehPQ7hNZpQmZ-u7I4NWPaRFvTXOxvK4MancllZJ_kr5FDasWwjtHwSnApaatt8UNb3ydw7d8V-ivAyK6jpoIpvl-5TcA2HFPg_qfdl-CJ-zBOWbAtch-HAm1vSWMW6s2OYfx3WPSl7nl67VaAwjEQQqUzsVvxf2satVsVpVRO4nLEq4a8na-45Z5CmB0BC2cRyOaok=w541-h961-no)

Next job is to check valve clearances to see if I need to change any, and then drop engine and back up in the air with the swingarm out :)
Title: Re: Nogs FJ Restoration Project
Post by: Rob the Nog on 18:25 - 4 March, 2019
So started checking the valve clearances today.

Got the bucket depressing tool (only cheap off ebay) and found it a right PITA to get it to hold the bucket down.

After finding most clearances were out anyway, decided pulling the cams would probably be the easiest method to avoid constantly messing around pulling each shim to measure and then reinsert to work out which to swap and how many to replace.


TDC, cylinder 1 cams opposite directions.
(https://lh3.googleusercontent.com/AZBrAn1imn9XOmkfYBb83FJ1DeXBSw4PefTNVc2o1EEPKULUf2DypgSfoCc7BCMfw-ZhNTC6UQ68GzjL6otC_hjKbtvBQ3vq4U0iRgAlwf3gvVBpv95GjyeGvLHRAF_af-R6t17whQNbKPplOaNIg5h2hZQOucr8d6iNWfl3886HKEHWnO_Hr3rePhHEyWsPqdAxQOfd3TjkaccXIpwpsGleGjCS8Y2Jye68qeE5qjBYssu3SaWJf-Db2tdXwBmLNXOmx84IybvW4S75reiKzVWeiA6qxagupjPItGELerksfhM4JZMAf_pTYGx1nDN5I-UT_X7UrV-YnD9uRz4cMDY-Zn0J6F5zSkHvlwu6vlzHDJGqtd4FLxqLaWhIldJZuDTZlNGEZioWz_JNJBYBRHnGrPzuz5mPaoltY_TPl8lTiYf35v9rLEHwxTfKtAsIrcj7aONnwRrGUem71OJC6LcUv7b67ylNsJGC6nw1liRwWQktX2TrGX6EmNPujt0U2DFdEFmfJvXRzIHRe70SuKe1lVmPE1FXsdue5aT6OQw16gJCsFk9yaOkX6uGDa13yewsBt6oYRyuMvhZaA0FvN9vv8pLB0xSc1Bzr9GkVBp-RMK7BOsy0sKr-ZyRLrrt0x5zqmsGJA7knhSoMo9XM_n8Pr6WBqurAf9TKxE8tOJeHsiYloCrCORnK-qG6d1EgmhMiKxOeClsvmAcRS9Wq-g-=w1112-h625-no)

Tape on chain to stop it dropping into crank and recording for orientation of the marks.
(https://lh3.googleusercontent.com/xCruSEy9is5BIG8n6CKQ28WEyOEI70gZLtQF0gEREBn7_JFZBXOElKGlRYc0RknmEdEpgdEGM2iIQd_REQrwWyERzdg95bntK8JvE9yprHHKODJ-s1ORp0QwnpL8SKezlvSyP5YAx_YYQhr6FEwu1hm6qB9lsOKbJM0ZKIa8DVlSBq-w3JvYTjChbZ5m6zTPR7DXOqu7TQCGCfUonAL-MaTgEfbY8RKqaDtiU7d0x_nfXksYzCik_7q0gR9k0VNbFe-Ge9BK1O-U835nF1fhhrnfdlq1-mp3G7h0IJSyJVoBivS7X9TDk5TEEQ8HcfC78WkrjTlHnfmu6zaEH5N8lcHWQQvbtQeVHA2aYPeFoMQ537P7yBMn6PCPuDQYoKXiqQdO8FtTPsAQcQMZ92gJOAq4lDrzFZQw2LbRwsaCDPjSTXgC-_2JvuFeNGiuqadAGqxj8H5i7IUcNjQtHwq95PvC3Ia9tjx3qPBNO4ZmIY4pDmeM7muEQzr4DPpZqLthmK4_685s5uUb5IO-g9BUGruFm80q25XHHeWT1r6VcdSmOwBb8xTZKCHycoh198etCRlLs5-OT27gQ_AIUJL1lQD2NA0xpc8HFEPb9oT0pezOmTniE6bOb7fe5eursNNv_PvCc5iHD-ErGu9hBbaGi4JXtY_H3jsBLmv1TUx4GriaYYehre1xVN4Qlvd2fcvkwkfLkIf0sBiMaMZu-u08SNAt=w1112-h625-no)

Cams all out ready to get knocked all over the garage floor.
(https://lh3.googleusercontent.com/tUT5PRIKHC7BtAXmjraF55UV58CpouLIu6pAKhyg6TobwF-tza0PEHQD_OV3Xf4A1YrEKTDHkl0m6olrcbvubqxuh_HDmc4simvXGY_rdOudKLV_ArH4khdNGGWLuf6nfeGafF1Ma5FlmSzPpKyRck3rvPELE79a_lOPD2d56z07dt0fhQwnYUYc8qFuAERHjk2F9Ohlh6LKd0nD-rapm2y76c-DvIipWEvLsyRB8F6ss9mTQky2a9EFV_Iqb4D5H_nrOSA3iKuXuL0TOHC3smLxKX4wFpvDEKoXKNir2wXINRcG12jHLYqdFVfAtBTEDohIDWUom9HoZJMPkk7IEFz6YpRefbe_2EC1V4vsWGsmHK9jqTm6YpC8ad5qfUKCd8kZmvAyr-0sBheZluWMC2-ZOkdcTuT6S03lvvl0vEFY7XLXngvNVk87jnuHAnm1UmBNzNYauGr4F7cUPfYtP-RNSiH-k8NJtXF7FBbXhoFL96tiooBq83wLmZRYVuaTzqbxNqHx6gV5bDAL-J0JS1sjqyk18eF36M7KEKVoVoaD4gNTbuE1nZGFuC2QVhYUHeLlBkFioXgk_CqfQtfIXOQXBeGDDORUkIi6XsqRbu28s1DwS2hhtBf6AJ93MMqfMZncTosUDosLGIxmk0mDRqDNbXAZp_h7seI-mNGGWYbG9T3wMxmAYGxIWWXpDrx9nyxOgr5968fcr2rVwczyx_WP=w352-h625-no)

A lot to change.  Have found a good few can be swapped but will need to buy around 7 2.70mm shims and a 2.68 and a 2.65/
Shims are 25mm, same as Triump (managed to find one of my old Daytona ones which saved buying a further shim  :cool)
(https://lh3.googleusercontent.com/pVWyX9mKFWp-jHgiD0sqhnuFXEz4edBFQO_dTFY9PuRueYeVv0K2q41vNrimLnuJbNvTwNDGuwLQUX-jSs31EieV7ZDB6zclKtyuT4lpSkxPA7NQXSPQ6hslQOx9DNbiNuLbYcfCPlmLudQuGSssi57OdZ4aUnDxGZiG3aQM_SZILZI8yhga0FcDzsvo_G3yHFLKVkfQ3IR2oS9yqabSTnhQAZtM6mtFyrbg8hEW_MAlvbOgWPz8NNEPSTSK3b5_OUFb6GdrsO1brekIVu5KpUhHng-L8oW1X230x8mGQcKDJiBqHGdbKzyR506IiXYVYA5UlLt0z7hFixueKUjBpZ6vxFi6t_tAJuhtkzHadr4N7nKkMnmUHkNwZwpSWubNkFkVevCNm62jUu479cKnnHJsRDzaTUlYWkKnywAUKnEuS1fhzluYOeloOHM4ZLlx6Fzk0-94DtXRo25D8eFfyuZgOhOmPZuSkQ5FyFwfrE4x_nbmGcHh_9v_lomHY0KXV02xZ_H3TxQ0w1E1KuiMrXBOllIAMAU-NwLVvRY8Re2j7XzK4sIxqf9VzRv5TxnoZLBwLE8pbpCKM73m33buib-Kl7O0afEUucpcD4TEgp5RdDbkAfF4XV2a0iMm0EpKMBgDCglakDERbqf2vCprMQGMYvHqkooCkDy6FnkKt06Ouf-8HuybJmqE-0nM0c1EfsXTHX53EQiPkYktQpYkseUM=w1112-h625-no)
Title: Re: Nogs FJ Restoration Project
Post by: Readmarx on 21:06 - 4 March, 2019
2.70 rings a bell.... I’ll have a look tomorrow as I might have one or two to send if needed
Title: Re: Nogs FJ Restoration Project
Post by: Rob the Nog on 21:10 - 4 March, 2019
Cheers fella, any left overs that fit would be worthy of a pint or two at SJ  :wink

I'll have around 10 or so spare after this so will keep for the future if anyone needs 2.75-2.85 sizes.
Title: Re: Nogs FJ Restoration Project
Post by: Readmarx on 21:23 - 4 March, 2019
Nuts... just went out an had a look and they’re gone - I’ve either packaged them up with the spares I sent to Wicky or to the bloke to whom I sold the old 885 Strumpet  :blush
Title: Re: Nogs FJ Restoration Project
Post by: Rob the Nog on 21:32 - 4 March, 2019
No worries fella, thanks for checking   :)
Title: Re: Nogs FJ Restoration Project
Post by: Readmarx on 21:40 - 4 March, 2019
I’d forgotten about the big clear out I did of all my old spares for the Yamaha and the Strumpet (what you have to do with 90’s bikes is keep spares!) - I do have a bag of clean and various pitch banjo bolts - all stainless steel. One is 1mm pitch double banjo bolt and brake light switch (though I think Yam’s are 1.25). Yours if you want them
Title: Re: Nogs FJ Restoration Project
Post by: Rob the Nog on 09:08 - 5 March, 2019
Not sure I need them, but depends if you want to clear them out or not.

If clearing out I'll take them and keep in case I do need them as I get closer to getting around to those area's or save for someone else's money pit  :wink
Title: Re: Nogs FJ Restoration Project
Post by: Rob the Nog on 10:41 - 5 March, 2019
Have ordered the shims I need - I worked out I can move most of the inlets to get the exhaust sizes I need, and I'm left with 9 shims I need to buy.

This place does them for only 2.38 each which is a great price compared to some silly money people want on ebay etc.

https://www.motorcycleproducts.co.uk/search_results.php?keywords=Tappet+Engine+Valve+Shim+25.00mm

I noticed they also do the carb inlet rubbers for a reasonable price (compared to ebay) so bit the bullet and got a set.  I didn't want to go down the spending money rabbit hole too much, but after some thought I agree with Readie that's it's not worth messing around with - once these are replaced it's something I wont have to worry about as I don't want to be pulling the carbs off every weekend to find issues once the bikes completed.
Title: Re: Nogs FJ Restoration Project
Post by: Rob the Nog on 20:01 - 6 March, 2019
Carb inlets and shims arrived today, great service from that company, next day delivery and I only paid for standard  :thumb
Title: Re: Nogs FJ Restoration Project
Post by: Rob the Nog on 14:49 - 9 March, 2019
New shims all in and clearances looking good now  :)

Popped the valve cover and spark plugs back in just to stop crap getting into the engine while I get the engine out.  Lowered it off the Abba stand and just got to work out how best to do this as it looks like that big old lump weighs a fair few kilos.  I'm thinking of putting my trolley jack under the engine and lowering onto some wood and then lifting the frame off the engine so I can slide the engine around a little bit on the wood to start blasting the old paint and crap off it for painting.

Anyway, looks like some big old bobber without the seat now the subframes off.

(https://lh3.googleusercontent.com/hLSdqbh1ZvkdX5jMNZ0HwC8QaPy5w4ZmrorR5751LNnSnMQm5ok_VXVUTSLPoC2ipch8thN2j6DslzvGdyfCvkTrSNp2Jz_UQb1qgrz_Qry_jP0TjBy3p5AHPWmGNmcXM2dSCegkiKybOa7gFD-W5lRk8eWO4ZEDyggHfgmb0nW_04ek6Ih_-Syl5FwEZuT_gTgH0xc96raHSVOmm9OHxDeadsl7apjzaLG05uGz83atCILhuLKBK3m_shEyjbSdI7U_SIJ8kJTEUcoT3I0f2rJ3iHrrUlL_gfG3BFW6cyfwwPjRgqPm-v2WPLlQsK0Gchok2EpB1mt8ChS30CVRxLksy0SK44z_VHnbncrBEq7gFMUbecM5kSY2MUElKrzQE8-v5on5SPsZ86-j9Z7LSzoIo1YJXyNlewgF0T5u7Y8OzBsukiS3XmmJBYdr7zI-ND1abKIfs4H0KjAo5wEDy9to05jolwnFJ9qRk0mjbOjGvQbSch9T1V1GASAhk6BGxu6ihpqAIqUSzZ2U3PdmfDlQq5gMpoHAAWqdQF_t7kcjJ5_A50yG_teb1EwivuUg8cXj_n1eqSnVbLgglM0Bf6F2fVPAXfB_mOa1PuLV5wMVJ9saCJqcwuQiQzRTcmIpcB_YOpnykG5EIycGk2-CFvtJGyhyqjlON4ay6pwdRGxyrwe0Ep7e45zeeIiECHIeJTTtPusyYHy-x9yYK6cbqDDP=w1542-h867-no)
Title: Re: Nogs FJ Restoration Project
Post by: Rob the Nog on 16:42 - 10 March, 2019
After a failed attempt to watch the first race of the BEMSEE season due to high winds closing the Dartford bridge and gridlocking the M25, I came back and got into the garage to start getting the engine out.

After some 'inventive' (dodgy) set up of trolley jack and tie down straps hanging from the ceiling, managed to wriggle the bugger out and drop it to the floor.  Few tricky bolts here and there but fortunately nothing seized and all eventually came away nicely.

Now ready for the main job of cleaning both the engine and frame up for a lick of paint :)

(https://lh3.googleusercontent.com/Q2HrlhDbU8yggYMiRIGdqBcuoJ9kh4GY23KXeiiy7n5tJH7yFf5hM4Q88IAUMqIrfFdRMrR6Ju_wHiEM9DH0lTkepMyUFyNdWEUobNROhwfGsWq6A4P7Y1qxiuitghkzX95VD0FvbvKBUKKnQGQN_iVM2Rd8yJg75I6tyB6CCkbITXQXG6bo1urKs2HTQ3GGeGACPyrIQPswJUirB-xUcXrAXmmkcsfkCFY5T6EMFZLQJ-iklK1PQg-861hYteeyDALInH4LIs3JZ2zCZpy2Z5MogdOeXLN3aXWN2r8lRxBM9D72o_jU2_9Ypgfio9N2vWiliTtiPIyDYT_hAgut6OdKUCU-3-7R0rbeXvyiqqa3ewi3vCZ2tKLlcX673XKnakVtLCEePslXYS9fRk3pL7hfc1iu2QncJk2kXb0EjMtPESYbLVSuu3HiiMUeGxsYJgAK2JJx6x78802g3jd1cnLxK0-w-fnTgsS14RQ_gwAr6amfl3Iz3-Z_El97O543tt0cOF2zw9migZckIAwt4mSleWP_j7JlCwyagbNxoVmbiiNSPwdrVT2aVhsyt7RM48v0g8oXQFJoErpOBeAIM5E2sYyHiwzxu79ZdKuykNI4olNefLr74S-BhH7ZFfPxzgyQa6OtOWj4OsHnolPVkTgFs-XhC9lGVBDzn-Kit0QEUfQS2vKtCFbA_NMmzEZWpU12kW_xYLYSV5LEY7Bshx6D=w1542-h867-no)

(https://lh3.googleusercontent.com/D9_FjmJ7Y7XlwS9GLPL0WeJM-v-qFVMjj5vg6_XZwmGfTEj2XJpx2NBAzU_ODVlbCbZs6iRb1wNTTLQ3nDhVZwroiWadBJph5HQjUuuSYyFYoYn7bPgldCVEj9UitpRq8_0-bBa_f-_qY_h1gyhluchpfmR_wAlISdpF2GIXJ_nWWaa01LQIlgi5PSA0D8WXobxbo6U53J-GLEe2W7vuj9mQ6CrBQR5uotq5vCk7s23ysy8XlDu-KzxVzla1hBtiAFOkVhpimBzNxywXEFLyPlGk__HxN7tKgxKvc-cvcfda2ixJk9mmoNMk5hXv-Svd95YlnzWT2mnwy-nAgnwt5L7DzC06UWO-FBe0HvCFW9UTh2A-sM3lWKIi7gTZJGsXAz5QpL5qTdFpTCRIzxbNm9MehtD-vYl1-ZiCz9n0uKSCn6q60xuIJG-WbnsSVONuwragtf1TqAT_KIXbFWXYPojNbohI9KVs6ZfAbkUw3tNcysOiY3swl6z4z-NuFmQBipX6mrJwhNipgJ6kA2rrYfSmxHyES50xNrkFjgUK2gDhWYj2bLWjAiLZ3wIitzjM7iLSiBFC7k59aRDh_wacQ3VBcHl1mqwWgW3k2Oxc0TGd5oWzpKvGFDGC9jaPLEMB9GPd_3pyc6KQRa-pNd6Pb1vDPXFcC3GkH9-Sil_pXIFX0fb4Oi7WXOCTKxP_JK5800g7hVmt_LGp-jNWNGuhqdgz=w1542-h867-no)

Pictures showing OK?
Title: Re: Nogs FJ Restoration Project
Post by: Rob the Nog on 15:43 - 11 March, 2019
Have ordered a little furniture remover dolly thing rated to 150kg, less than a tenner off fleabay and perfect size for wheeling the engine around on.

Can get it outside the garage door then for some degreasing action to ready for painting.

Thinking of giving soda blasting a go as I have the nozzle that came with my compressor that will supposedly do it.  Never done it, so maybe simply for shits and giggles to see if it works and try something new.

If not the old gunk and stiff brush/hose pipe should do the job and then sand/wire wheel any stubborn areas.
Title: Re: Nogs FJ Restoration Project
Post by: Rob the Nog on 19:17 - 24 March, 2019
Started stripping the swingarm today.

Although mucky as anything, I was surprised nothing was seized or tricky, came apart nicely and then sat over my washing up bowl parts washer with a stiff brush and paraffin scrubbing all the old chain oil and crud off.

Came up pretty well, so much so that the swingarm shouldn't need any paint at all, only really the bottom shock linkage has took the brunt of road crap and will need a good clean and paint.

Bushes in the one linkage could probably do with replacing, but the needle bearings in the swingarm look fine, no sign of rust or any wear needing replacing, so will clean up and re-grease when re-fitting.

(https://lh3.googleusercontent.com/FxYeG4sB3Cj4C5g0rxIQYoTfPdM_0IQRl5xCPfFdc1q3JO5A9ajkOOVwWHJdAXQjvsUqCT7OVt218Zmt8lUUjWLTBGegnd0CMcVOVEFnjDqj9vFkbYZqDgRLMYVJUw-KG3rb10xjJt8zbuBltY3brJq4EBsMxgaAQE_oetDVUJVyBqxOn7DNhPi_gHOW1ZCPf4yMCSaT1FQLsxRY_agf6-6EKUfz3vOktPbcLcsJGCgi0Lks8FHH1Cwxl5rh6DpjTyoToGIj0U6WHKl_7J3YKcREsKB6lmddCoLCo6Ivn_UC7VEAtovGe4mucuVoyW9XWxMu6pmMQb26UcNJSSE4F3Gle3Y8rTRYqaGMTXw9zY63gFOMoS8hIJGDxjxDUcTXYRegKeLBqDHref0Oj-bodhvr4HXpYfW2WxAzlbcaP01cQIA6VGeUKMywVVirIKiADSblgac22P3GO6BHADXHYiZiImD34ZwGhlRODxpNvDUH8tWruvkS9EZAztC8kB_SLCwwfW2qxh7yrI-5lLBeVglzzTdWsW1fnmT4C5RSwpn76N66v-WvujoT9htrLbkadnxaWW9Bczs6rcbs07wvdClS5NnJUKg6qilgv6sYC4F-qB0zwzVUR_w5yXcch42M3ihL-ADFXhJh4x0jhRCcwjbaS2wPic0fv1kqjlEEsde2Ni97DCrsNWUENC_X2YGKhZuJUt0zA1BztdR4PhBab2BN=w489-h867-no)

There's spring compressors on the shock simply so can I move the spring away from the mounts to clean fully.  Shock is Hagon which not sure is OEM, but looks in good nick still.  Looking at it I doubt it's the original though.  Might risk it back in and see how it goes.

Started to clean the shock mount on the frame, but that will all need going over much more ready for painting.

(https://lh3.googleusercontent.com/OfxhonKmbRmd4Vhg9sC8ophZDK7I6tvnINyWy1BV73lyfWEIugYw5kvdUysafLtcWUCbygIT68a2MW7mIHxE4WjujCvDBbQmjCHz58Wnsa6KN6paXUvNjSnkWc-oP86N2FNmN3dQi3XqVrBssqNE0OVtgP9invCQ2rD-26kv6cGSvUgMMuE7gfGDNj4dLUzE2mu_2Y9qB7Bx64JZZHsis3ApuA-ziu_JPZTV_aIDR6DnEaLxxkpwW6S2gMTz95nTG6R8Of3vnadHYlHfAVpFV5Lzb-ge4edQx3Hk3y0UaohYjmeMZfOYPiwZ8UvFk3MCwphuia0jHTCCuT77EjAua8uHJhIXlQSylR89ihpKqeqU3xU7RCcFxZT1V1UuXy221WWMLnxuzv-CFPQ1xsLpanX0JjD-NADyK3E1xNNxVxNVFPnSyppn2U_upO88bToGFgOmYB7R6vjs1qXWRflbKpXkleV59L-LXg8dbbOB06K08sqnQ-BTKIr2X6MFYEVjKrmh-CXd1et-Dgd_8afBf6zpkw8c0cAq0y_LYeHQBWJJi0_X5Qc-JidRBTEkG0zmq2JHricdZH87_pIgN2eJmVmlSc7vTu1YYCu79NK0T-AZPa34bjXrzaA5u1BUpJVyzccN99iS6pe1FzrehzCokJ_EVhcn0UCZk8XucCoCoKtV5PVVKsMIASyHqRuYX6lP1xOyO_nc0GghwWspf6xOw0CW=w1542-h867-no)

When all this is rebuilt I'll cry if it starts raining out on a ride.
Title: Re: Nogs FJ Restoration Project
Post by: Rob the Nog on 09:24 - 1 April, 2019
Started attacked the frame with the wire wheel yesterday.  No pictures as it's basically looks the same, just without so much flaky paint on it.

Going to take longer than I thought to get the job done properly, did all the main easy to get to parts, but will need to get in with the dremel to get into all the little brackets and tight areas.

Got a bag of small scotchbright wheels for the dremel (well cheap dremel copy) which should hopefully do the job.

Once done can give the frame a wipe down with degreaser and then start respraying.  Painted the suspension linkage and came up nice, the 'steel wheel' paint is great stuff, good match for the colour and seems to cover well with a decent tough coating.
Title: Re: Nogs FJ Restoration Project
Post by: Rob the Nog on 08:29 - 8 April, 2019
Work's slowed a little due to other bikes being a pain and needing work.  Have started some of the paint stripping / re-spraying though.

Cleaned up the frame lowers and got one primed and then sprayed.  Has come up nice, a little pitting still evident on close inspection but there's only so much turd polishing I can manage, overall it looks fine and is solid enough.

Will post up a before and after pic once I get the second one done - that's the side under the output sprocket so needs a fair bit of degreasing first.

The missus is away for a couple of days too, so I might bring the carbs into the house so I can put the new float valves etc in while watching TV  ;)  Will just have to hide any evidence  :wife
Title: Re: Nogs FJ Restoration Project
Post by: Rob the Nog on 15:33 - 10 April, 2019
In a bit of a pickle over the FJ carbs (more bloody carb issues).

I've got the service kit, new float valves, gaskets and o-rings etc.

Trouble is the float pins are stuck solid.  Been tapping away with a drift and hammer (gently) for ages the other night and getting no where.  Tried soaking in WD40, heating the posts, still not budging.

I don't want to risk getting too brutal with them as the posts are only weak castings and if they break it's game over.

So, do I just risk the old valves etc all being ok and simply leave as is or keep tapping away trying to free them up with the risk of damage - the carbs are becoming like rocking horse whatsit for these and cost a lot and then could be in the same boat, so really don't want to risk damaging them.  The age of the bike and carbs, I'd worry after putting back together the valves might leak and overfill the bowls, then it's all a PITA to get to again, so I'd like to change if I can.

Any tips / idea's?
Title: Re: Nogs FJ Restoration Project
Post by: Readmarx on 22:05 - 10 April, 2019
I’ve not had that before. Without a pic I’m stumped. I’ve only ever seen a pin securing a float through the body of the valve housing. The tolerance is generous as the floats move under such tiny forces of feud level. It was running when you got it and would go up and down Rev range and idle after that?
Title: Re: Nogs FJ Restoration Project
Post by: Rob the Nog on 08:22 - 11 April, 2019
Don't have sonic bath big enough, will try a blast and soak in carb cleaner.

Looking around online and people seem to really rate using a spring loaded centre punch on them.  Apparently the trick is to brace the posts with a socket or something, blunt the end of the punch so it doesn't spread the end of the pin, and then keep firing it in until it eventually starts to give.  I guess the idea is the punch isn't strong enough to break the posts and by being able to hold in one hand you can brace the back post enough to get the force to go through the pin better.

Got a punch being delivered today (Amazon special for a few quid) that comes with 3 tips so I can blunt one down specifically for the task.
Title: Re: Nogs FJ Restoration Project
Post by: Rob the Nog on 19:36 - 11 April, 2019
Well bugger me, put the punch on the pin, braced the posts and pushed to trigger the punch.  The pin dislodged instantly  :hello2

Got all 4 out so easily you'd think it was a tool specifically designed to do that job. Bloody brilliant tip that.

So at least can service the carbs now  :thumb
Title: Re: Nogs FJ Restoration Project
Post by: Rob the Nog on 19:49 - 14 April, 2019
Carbs had all the service guff replaced, just got to check/set float height and then can put to one side for the rest to get done.
Title: Re: Nogs FJ Restoration Project
Post by: Rob the Nog on 19:48 - 17 April, 2019
Time for the front end to come off.  Stripped off calipers, wheel, forks and steering stem etc.

(https://lh3.googleusercontent.com/z32ub2dkPhnA4u6CeXRvxEd2RcSNleB0g696mJS_UN2cpAGGhqyCEhsmXoXJA-dgCZV5sywjV_xr6li6N7eCP-KajMsUPlLBF6mvsvmZhbQ7izGSqFUCCHemC1KZM2lWPtlVFhZEf_vrtS1bDMbxbvujb3QNK9DaecbTACI1S_5wUMmECuyn7o47LOBw3BoQpREgsQByfG6j99zLuOe6Ib86DV8WcLF639f7sgPHQiYTktDx9NsC4PRK5LUUlbeRjBWVQFIwBIFauN3tAI3QA-oFuSFiHxMoDnflrJtWvAtuhgNpFT6JeDWnT0pcbX1eQqBudYX7Nn0FexAd11WMqjBNVvcjHHqGQxAPaCc23LY8AQAXWuvu8uPWMDBPEXAKyLpYlJWKJkfd365AhyfJJWh81yNedMmpTuLfWZOGFxjzFsjxKYdrwjxYpx2m6p5w8sGaP5TdjrVIrT0cl4sWydBbRGSVMvMGXhSCHYF6NLfsFaw6ntz8ei6dM4EDDcpn141FMdFu7rlTezYZJcNXZUk69szZ3axQlueUPCo72TdVskLUxbm_QyzSNL5qpsKCHMl1t8B9YFfR8dhz4sV6w7VAVq9tuUrNB0Uj9mAjRzOgwl3gEvKqHJu4wo5h2VvpbMkT7LaD-zcVmstZpcORtcjhlLggVdWsE8iNNqZh8rHlL9oLdmcltEVSn-a0gDrxdP21LAJcmmmR4ZBHxcFPtAoc=w1542-h867-no)

Not much left, you'd hardly believe a bike exists in 2 boxes and an assortment of jumble.

Steering stem felt a little notchy, checked the races and they look fairly worn, have ordered new bearings, only 20 quid for the lot so not worth messing about with.

(https://lh3.googleusercontent.com/KOAdJeM4FRUrv9dZ7AkIf-CkD0e6tQUK1U4C1cNdQZxXKrV_soE4BVJZ8M2ycgr_hy4jQgZiwQSrIDXuokvlz5YuyxLktcwVws1mtam1dT8iMmloBTTX2UDsb4VDM97d5TVydAIeCJiZaYLIGLtgX5ennfTYH2isCBdQYqLNbP7Ar6hRAaCUoUV2NGmy-Z53O2BHhB_ZJ-3rNL-msQrvX7Lhtv-ogXK9tvXH_VO_R-ezB5dA0ZE1YsPvREUCFtf1eX0gKnUvSbu4OAbWNg0BjlC1FRuuOQJpKZEozpy6QBl5xG9efqh9q3cEgvWgcL3Vx_arQ-5vxbut2_nkLR70E6vkwkZVArOxLIIOF5WwLDZS9RSYhtBmFXYpRfXa5yjjkBcj1xjr_rZbUt6DsFgKgwQz2ApLqvesvtpkUqfg0R5AxB_DnZMzAnpA99fAWwVUTz80m0uCEQ-wiJSNCO-RwoFz-6tTGnYDJJNyAmZTrQU5iYFtWWzXvBOcvIDF9s2OMaKr1LY3e_yOG_PsVdFAzqUqMao3xjQqRE1yFMhsqkFXDl1lXaP_V1QIBr3z3GuhW3rJEjZcEGydLkpuLmeFA3jyXdoSjDHPgsjmFSegNjSYo3uymyGmLaWQAqNMa0a4v52MhqElHOkp4bQE1pYT47I7ED5SLgdbeFgfIhNcLy4nwzfmT0cd1Smf9SVGilkVO8qOkP4rPQfTpU0JaZ0owwjc=w1542-h867-no)

(https://lh3.googleusercontent.com/P6U3vUwPf1SpImOFAb99NyqeVXk8QF_do9zxpPHupsoWJG4jX2CIOOKrltj-IENYprI4VAfEu-vFol0NhU-QbWK4gE3sKuZF9XV0nkfFIe8E5frCxIuLPCDBPzPKCftuN-JoV94MIdbplJVZQdhE8VTKde88GajK1_igAcfKd9buROgWggGArlX5va6pHvZfDR-j3JFDceNIX3zo7k3-TOLepLqEu2JuzOGShOCTRqFMzakp6XK3HAljahHVFnodXa3pm769Ejg8JwQVZ9EnD2WN4QnT0HJZkwGHN4gt85XCVJs7LflTYt5HT3_HcTx0kC5w0R-jFmW7hoRthox6OPGUNWOxsBeFUXz0zOLdUyyaJrmcwxooK5phTOBzEgLwcYKlhBMf6DHIIm_nuFgaQpKsEgq1Y_lPdZevSmNNhYR-CXvHU4SqkGeoqe2p066Hntk301dnrv1Yxe9Q8TPiJyXJJux3gwgNta6YT6GVRA6qdxqWaoF0N2yvOX6bTWgr3Fisu4EP_SzGXTm5n0H-Vv0n41SBY3tJ7nAOZTAXYrkyrfBPCMPzTj2HcegXB8-LQMj-LYbzVxAu1xcV56-WnIFzen_-q9CdUMis6bjFPPBX7Gwx4rP0mYiCJs4slkaWuMjitmQMIGeDWno9U6h9qiwRuNPp0NO_9PeZjRpqVfGY8yfoAsS9FgbakdJfWZKYtWLRS67Nv7_OhMroWbxBrQUp=w1542-h867-no)

Will clean the frame up while waiting for the bearings and get it ready to spray up.

Here's the lower frame rails before and after, really pleased with how they've come up  :)

(https://lh3.googleusercontent.com/XQDiu2G0HCe8aOdiCaSCPan7FBhmhKJcB--Vmqp0YY0jnUi29xoYVPFK7noOvhFdrtfYqUUn229VPI3go2dmnRSbWxPO6_WjxCNG8_pyOV-W9uioWxGIfIT8Dvy7xsWfgbVq5aJbVHsBAehu6XzPlXwpuITnlqv1kjKGTQsuuwweqOP_jxeWRl_RNzULNkosynxzAp4X44gv1-8nxnbfR6zuK-xkO3o6eK3PWo8jiI9bZRKj2dQDsWV8u5DZlUxGGrI0F30krHNySBH_k3hTMVmCyM2-H7V0ThcZShkjDMaKFtHgdwavXldPm5I2bKxXutVSeM9doO-Y7Oc6iY8dq5lxukCIdvmG-l0Hua9CCnr2IjnjrBk20_qP-0qrN3-p_nCl1rPbEV1ixd5tEJqUwykX775zkprxfmS1JK4cOhsNoErFKXYid2miUQTBWomq22a2yqoxvo_-bxRco6MAiDKH-kgHj9FL6CaAwpesU2wMPw50HB1Ue-Cj4upD6hj9_-EtrJjIjsLlY2KoOcNVroegkeXUd2cU5MDs5zuXPfY0P7T2UFGo-8u6BvYsZf3MRcgveYjZGK8Gwfdkik6YGDLy9OHEs87y9MXUIRfxbsnBHZ6Di_FuK_GuSxjZ8WNT_AR8D3OY-0LeUPKDpvadcSloK_t6A8awrsOUG8_lKMj_QsZUElfxkxPwPQDFC4nZwmcKTj1SFR6xvC8FN7x_Dt7f=w1542-h867-no)

(https://lh3.googleusercontent.com/05UgoYwwp6rA9K_YgQuAwF1Ldd-XEYETmA3ptwjS5luL1Jt36VjlUM84YmBdaWhd8ptUVKBxjffxZ2wAlSlezpXHgtj1h1A1-aP25JIKFO0vDF8uvfAX9PesObeO5HVNp5leuxT6ydPeiZCSwQu2tWVUMXsIei7tKPSJproGp9IX21geW9-7GmzBmW4ZKEXghZUs76iJQlOu8bz6pVHmyKKplvspTeUsjJhBQ36z_AA_PRO-U7H9G-L-u6_Xw8QLcg-8d8Xe1UE85HRMqi4I9T0jNxTuxxosca3jwFGUqppMEyv5MkigYJhqlBgPonQL7PgE9U8TSTIFbejAZuoMPflEyB4AGvSqoS6OncMlvTCT8U918Upp1ClB2lTp8fNlai7ige-1B3RHi2hffWxlFqWEAjjeVMuNK_5KdVq0K2SjNGKAYfwp8ta_rgTE_s1_8rDL9D0MuWsBoWoqLS10TI2aThva54Rmfw7Il0oywAEnmVINctrlFY7e60kQHLGEdlrf_RvJSaXxtGJ2wnzyl5wPmlDZdznpapEGE40yDEbQ7ITpjf0rgljgaq-uZ4_EaNGNXM11WN_SD3HnBZ9IaGPp-ppEUIPr81iKd33-9j_z9UtE6X6On1aSo1i9Db5dpx1WypDnN2Sf0D1EIMdEAbLmESjFdfOOL38VdGcdQB2jFA1La9wHGDuqMmvPSi2lwTYRYVk_r_z1rKLjurl7UYaT=w489-h867-no)

The Simoniz Wheel Steel is really good paint for a silver frame, not a bad match and goes on great over the primer.
Title: Re: Nogs FJ Restoration Project
Post by: Readmarx on 19:55 - 17 April, 2019
Spray looks good

Steering bearings... hate doing that... never had a bike that was easy to get the cups out of and always hate getting them off of the stem!
Title: Re: Nogs FJ Restoration Project
Post by: Rob the Nog on 20:05 - 17 April, 2019
Yeah I noticed there is hardly any of the bottom race proud of the frame.  I've seen a tip online where a guy built up a decent glob of weld on the race so there's something to get purchase on and the heat helps to dislodge it.  Will look into that more.

Also the bottom stem race looks a right PITA - the manual even says don't bother replacing unless you have to, and if so use a puller or cutter.

Again will look up some tips on this - any tips welcome.  Is trying to split the race off the stem with a dremel grinding disk worth a shot or too risky in case of a slip?  It seems too risky but the thought popped in my head so wondering if it's a good idea or bloody stupid one.
Title: Re: Nogs FJ Restoration Project
Post by: Zippy on 21:05 - 17 April, 2019
Can't you hammer it from t'other side?
I have a blind bearing puller stuff too.
Be careful with the welding... in theory it will work as it will shrink the race...but then if it doesn't work, it will be a pain to cut off!

Swing arms look sminky by the way. Nice work.
Title: Re: Nogs FJ Restoration Project
Post by: Vu Ja Dave on 23:15 - 17 April, 2019
I seem to remember on the TDM there was a wee notch in the frame so the bearing cup could be knocked out with a drift.
It was still a bugger to do.
Have a clean and rummage.
Title: Re: Nogs FJ Restoration Project
Post by: Rob the Nog on 08:20 - 18 April, 2019
Nice one, will have a mooch around in there once cleaned up.

Just got to decide whether to simply hammer the new races in with the old ones, or play with making a puller out of ally and a length of threaded bar.
Title: Re: Nogs FJ Restoration Project
Post by: Rob the Nog on 20:22 - 18 April, 2019
Managed to get the cups out

(https://lh3.googleusercontent.com/7F8yG3NcqxMFVyXjyL2rfKjElYQELboAgWeDaR_OlcdPKkbCbRaKeeOGzmQm4MXUtQjYkTxg6dwH-wYLRMTXRtHEEv7KG5fzqMvsd_LyEjRtVisaJSaPuiPWk20uALH3hKCIDTv8KgVaA6YKIaXY3OrNtMRWNKA2FihhxQp7rjsLpT_HFy5qeXoSC-MbvmbnXwoi_ehj5KoRXIKmfZU_rvCs5ricjlEiCB6H0ZkCUuWnX44_J0LWbSkapoiR4J3dXdx_OmHTEGo9frkY9RKfC-pELS9fOjAyrwnAjvMSSMUWnRigdED6avZ1Svfo3bOSG23HH6gDt1_M7006CWp8y_lfiTo3dY9_GylKGvphnbFveCb076K5mdliH_aiuZJiPrn4U0oluLEecTLHGv517pk0uAq6y6dUr2F3bMUa5eIgaFiY4dJrqGf9ze__LmFUGnsR9Q8s7vl4e-_QH5SuELHDGmHteTXLdkc30iSgOTXbU1q3lh0KcncGzgLyayc65v4_CgCc3IRY65K3_AkMMZHRM9JvwsxootdtNh3mO42Pu6VHCBCeWUUxnYYp_rtGL8FJDBPviWa6cDHDbmKs76NOsrBuC3Sd7lIevnR4FHmz4ee05E-mANzhqzBV75wAQzHA9gqi7nPPvZOLbevBVbmRU3qGOiOVB7Wcf4eY-OU2rDOZY8D-AgIZVhqOjfJP3Z7_mWM_9vPwFwC7eEBJM_f_=w1542-h867-no)


Bit crude but went for the weld option in the end, worked well and doubt I'd got any purchase on them without.

The race on the stem wouldn't budge, broke away the outer cage and tried to chisel off but the edges were snapping off which I've never had before.  Tried the dremel (copy) with a grinder disc and ate into it enough to be able to split it with a screwdriver and tap it off.  Like I say, bit crude but worked.

(https://lh3.googleusercontent.com/NEKtPZRlwPoFDuZpFsnnBiXm0If6uL4ql7iR4lG_nPIn300QWvgRPEQ_VJJak2y9VsX_JX6GZFcyoSw6Kb1tZPKQx_qgYhoko3q5-kcF5EdJDSjVClfIcnapjAW5rN7oRVojERUYLsaVNBpAC_Qj3ud4HY4Dgfsxy5R5q39h5vPE5PYOTpFoBG8jdYjCvjwioTQdbrGm6p3DwteYBUfGrl4emdN7JISMJSwTLRPB2iEiSX4xcG6yKrvACfQrma3YoDTjJfsLs2lCTe2pz7SK-JSd9Jql6dNlU_opXsyp6roF-SUfGbSwtd0eJWBcS9k35oRNn3xNDGmBcP9TSz4MnyUU2rgqIw-M6sR24SHyEBlZ_KZQqwZW20TcBVD5U0nPZ7knv2jKvL9lBaBX0eqe0_01NNLMQb0DKqbXLg2SU-TR-cGQQIJ3zNPaD1xjnWzP76o1uWHIBsf6in-_ZJb_FoL52BCrCdpVz2IhqM6cOfaoRc-KYgOoeYOXRbfDNc8-oVvA34jMeAiZHRbnWyTgbcl49K5jDF5BroOWMYlg7JQm6x21MgekOZuIuHlvz4XWP7w_ECJH_twQB-GPUPRxH5lmB9kUhIAyPgSsxPoDGj5psrjkFrRwgFz55wEqQMkWBwPdhEArwo52SNSqS0Pq0jMstG3e9hJjD0dhfdoXr2tTWw0JfE8hniE9LvWQrbezERfpJdsYpKAAG-4vKNUBPwRi=w1542-h867-no)

Looking forward to getting the frame sorted as can start to slowly start reassembly  :cheese
Title: Re: Nogs FJ Restoration Project
Post by: Readmarx on 21:51 - 18 April, 2019
Nice with the dremmel!

Title: Re: Nogs FJ Restoration Project
Post by: AlunL on 23:05 - 18 April, 2019
Did you decide on the colour of the bodywork Nog? Was it black’n’gold?
Title: Re: Nogs FJ Restoration Project
Post by: Rob the Nog on 08:36 - 19 April, 2019
Still undecided, was going to keep it black and red, but I do really like the idea of black and gold - my brother nabbed the JPS scalextric car that I wanted when I was a kid and i always liked that colour scheme ;)
Title: Re: Nogs FJ Restoration Project
Post by: AlunL on 09:15 - 19 April, 2019
Loved the JPS bikes.

Black and Gold looks great on the FJ12.

(https://uploads.tapatalk-cdn.com/20190419/bc08a32943cdda79f9673f1a9c1849ef.jpg)
Title: Re: Nogs FJ Restoration Project
Post by: E.T. on 13:01 - 19 April, 2019
Black n gold is ver handsome
Title: Re: Nogs FJ Restoration Project
Post by: Rob the Nog on 08:39 - 23 April, 2019
Good bank holiday fettling - cleaned the frame up fully and primed completely with an anti-rust primer.

Once dry laid down a good 3 - 4 coats of the silver and built up a nice decent layer.  A couple of annoying runs in a couple of parts, but nothing to worry about and the whole frame is really nicely prepped now.

(https://lh3.googleusercontent.com/LmsP3bOB3pSzPQBpg-v20c3AkSUk9oncYZEBusa2V3OhvmxOXZ5930b6mVdcETpZOIa-FvtD9A2m5zJLHUA2c5EkJloHotaKrna1s6pAgN8o6SgDgyWrWlqQEKTEXbM4PjtxJRS0V_EtAi-WoMVEJh6d2dwGJwC4QX2kBS6OxCeY2qP88VRSYYxlsxBSONYSm1PIQZQnCiBo9f_f0UgBcisAUpswwANqTAr43FKc610RI-zvz2ldayjZwWzeLo5OVd7rnwbH4_fMw2hyBgtAKYTkqglh7KIfmnWuOrJGn4b-VGkr20lqd2wK5hm9nqAcmaQ80VTA64vgck_4eRbzdBYOc8i1tOuOn8ATo_lnezaowzy422bjzfNRy-TKYPQTrKAhsxYZUhFx3n85JtCGF22RcjBjK_rqLPwMtKkF35Wk7oFFa340H7JR3uf-yJK9okmnNFEMRNcTxggC1NNO0rkO88musGrGZk1aQoirlWKJjZ2wiCqtHTlp5iQd_t1wfoYW5gAce5B3Lnmj-fOXJAv5jYznbo6p9PqTEZ3cYUMsgVAGBFLX1d20c9PkUL41yoeymNmJPbJW64F1VGcsMtAiufpvTD_kewm3DHe2F_7j598Ne4J4bjI4tbplzxRbAgTriJASVvzckKQtP15EjkDhRJs4rUY=w1709-h961-no)

Once dry got the new cups in, loaded up the new bearings with grease and fitting the stem.

Also stripped the paint off the top yoke and polished up.  Came up really nicely and wondering whether to paint or leave just as clean ally.
Title: Re: Nogs FJ Restoration Project
Post by: Rob the Nog on 09:42 - 24 April, 2019
Mounted the swingarm back on last night.

Just fitted without torquing up at the moment as need to put the chain on over it first of course, but wanted to check for free play and it's looking pretty good, few mm I reckon which should be fine for MOT - the FJ forum reckons 5mm travel is not unusual even with completely new bushes etc so sounds ok.  All the bearings packed back up with new grease, nothing looked too worn, so overall was pretty happy with it.  Moves nice and smoothly anyway - must be more lube in there now than a geriatric swingers club  ;).

(https://lh3.googleusercontent.com/WgicFqWFWY0UMtTSkG-YMsBn84fIzhnXdENHqP8hqRrRUbyarPtf0FPgapXt4j77oM9F8sNwACtwa4VaRTd3ckjcOQSeHZhIYjzkF9LDbpP4BxRA6oZrdlud8ODfB1-dDMMW1UM8r5arsOJiAzQi3V6Z-hAOeEHvpxermgD53p89UElMDqABmxktomNG4_zAUfMVmra5GGlBRtwkhL51_1kRvDPVBuYOabPD9InVPH5vsCjLEg_afyu3Ho7m81VVQgCSI4_nRfBpYZ-8_hqmrwQ6ce-uH8xFUddjqp3-KOePrrNT_MIKFJVeQ9519QGboxlzblAjCdYGNAoSxwZiN9UgjqEcVsEPp68s5NzXnwRvy_T1lPZIs1lVrdt9wm5YCM5Ra71-cd4mG0285bf0jmSrfr0NB3GvbIsXdAU84J_xl4YI_H-JULcAwPHUD_u4ePXLj8WHItw06ifGxV6NxeSxdZIUaQiVZosYD6YofkkqTGJnIYsynAeVuzmP7kytRg1Sgz2hal1uIM32aN9-JV3dg1z1EdoIroxL-TZ018_rQSe1dG2F4n76fyBOV-ewrAJT6vpfAv6cnSIbDeWSvlV1Kw20kaFcGKGaSQKx3uALPfodgg2mTRmElvWxME_Bco6joTFlRv-MMDGlaKsx97_eAXibqd8=w560-h995-no)

Bit of stone chipping to the swingarm around the shock, but I think I'd rather keep it as is that try and respray, as once the paint chips from wear and tear will just look more ropey.
Title: Re: Nogs FJ Restoration Project
Post by: Rob the Nog on 13:13 - 25 April, 2019
Had a bit of a "D'oh" moment yesterday.

Was fitting the footpeg/exhaust holder brackets on yesterday and realised I'd "lost" one of the footpeg bolts as I could only find 3  :shock

Spent ages looking and couldn't find the missing bolt.  Came in today and was looking at the exploded diagram on Fowlers website (worryingly they were discontinued ages ago) and spotted the left footpeg has the lower bolt with an extended section on it.

Then realised it's the bolt with a shaft on it for the gear selector to fit onto and I taped it to the selector arm so I wouldn't lose it :bag.


Anyway, few bits to paint next - footpeg bases, torque arm and centre stand.
Title: Re: Nogs FJ Restoration Project
Post by: CoxyLaad on 14:18 - 25 April, 2019
great isnt it when take something to bits and dont put it straight back together  :shock
Title: Re: Nogs FJ Restoration Project
Post by: Rob the Nog on 15:04 - 15 May, 2019
Been a bit quiet but hoping to get back onto this soon.

The Tracer purchase and TDM sale has taken up a bit of time and got the set of TDM knobbly tyres and R6 front wheel to sort out and flog too.

Not to mention the wife had me pruning bloody tree's in the garden at the weekend  :wife

Normal service to be resumed soon.
Title: Re: Nogs FJ Restoration Project
Post by: CoxyLaad on 13:32 - 16 May, 2019
women.
Title: Re: Nogs FJ Restoration Project
Post by: Rob the Nog on 13:37 - 16 May, 2019
women.

Lol, my Dad always joked if it hadn't been for getting married he'd have a line of Rolls Royce's up the road instead of getting his hands dirty working shifts.

I think part of him wasn't joking too  :cheese.
Title: Re: Nogs FJ Restoration Project
Post by: Rob the Nog on 09:35 - 17 May, 2019
Got back to it last night, changed the fork seals and replaced the oil.  Started cleaning up the fork legs too, think i'll probably paint them as the finish is pretty poor from years of stone chips, so will give it a fresh coat to tidy it all up.

No photo's, you've seen fork seals before  ;)
Title: Re: Nogs FJ Restoration Project
Post by: Rob the Nog on 20:33 - 21 May, 2019
Started prep'ing the fork bottoms for painting and also stripped the subframe ready for stripping off the rust and flaky paint.

(https://lh3.googleusercontent.com/i2O4reFBS-emtilK1kaMYrRHbL6zZydoywrJucd0G9uvMZ-Muy36hJeWlLH7qpv5ZBWgsrrMAaf5dlvWyf1t-HOOmY7cWL8ZjcIT5G2ibYlkn0kWMRhvIPm7IBqpMM5GwVoVAFia_ryXQ5Rb1iQIWCYOPQJ2zEMmJHHCb5pghKWlzi3ahT47qgbhTZRKvElbp8vdqAGysv7mYfq2vTMGwwzYFmryJtQWwIeG30P6hPG-44BHlPNnujqWKsaSYIMxMs_iGH1nFaJVKZFrneXsmLFopOSO5XxLgt87pshNIJDztObGOx2T8HGs9BuU3ed-bTT3WbcCWRw3lPq6gWTNxqR5ELSkbRtDE4fdRjTWL-4EJwEE9BdhY6nwsSlJPoGxszTGASuX5P7m6MkHPk4Jx0hXV-PdU3hwY12sipwWgQS7mF_bDZNQxk6KyeSFZ3P4RMVDrOjq1vmvWnvBmV5fhRWWwusDVRXsi4RIMevPb9AxJEZG9Tp9Q6_-EURwp6GUER-HlwWxu9X3Uo3htfgHm4KG35cYQFNaDCGZL0dqtYF_FE38CQfEjR5-HFhB2X1fzJ09RsJ-BjPuFaOdER6SmYRyzgb78Ciq6sJmLmP9589K1kYOlBOb5YNLzN6nFMXg2UUp5I7QX8q2jfk7HlWGHe9dr2B2j9U=w489-h867-no)

Battery box is also off now, could really do with blasting to be honest, still might look into getting a bag of soda and see if my compressor is up to the job using the blasting nozzle that came with it.  Probably a bit pony but as long as it does the job eventually might be worth a shot.

They don't make indicators like this anymore (fortunately), bloody whoppers.
(https://lh3.googleusercontent.com/MW5tU8Q53bKYqtrQEFGT4lp80pWHNJSAc9kaTJBGTbx3Qc3knV1T0EJkSUmJma-8QWwaaV4RsvyA_nd4wzbYKJPOpab7fwwJp8dF1WO7UpvDMEEZJtVXdRX10fUVXADdiVmSL6j_LWLNVBGt4GTU4fw23ZrnjOOysj-Zam2BI9sCap3_5IHf47e6jBu_9lWC3cORZm_bQALzdiiehhhbMDIGoYfviQmXyRtbhaIca6y-fls7D36fNbS6D5qS58rXYIdwTHV0-1vyWfJJXBORBBC6Q4RPnfKj5eJnNwlNd42ll08vcs-XYOPHWGx1znMHhdOLwud3h4NalkAc_He-JYAEi_Y15lECkrZq5_9wC4dBTP3hHSj0jm9xcXYI9Cmy-A4LfAdq9o7eBw8k-iFnmc3yRGs1L--j-S6-2NVNqkqcL-guvHjxzzMRNjuXGrBi0SQ_57ghYkNjAka2b3B5-vXOznwSTXOm6zYTyEH2bUPbxWS4xtv6d5nIhHpaT7yt0z1Xu4dCGclQnn-ofsj5HTIWzkeDBbuSXnG7RyGO-zQ_-Tm1fDNfNbi6IADKbptNAwVh1YZVNN-ya6k8oC85Tf1CkOxiPgJEEEPVu9gUGmFos2pd8ZX3kQaJ6UhycGnpOLQvtLC6UP6bPiTmbH-gf1fbMg91gZkIM3stPHet-R0VqSRDdJwrLO_4gSc3Eq8ly1lWepiogsJa7UC3Ky8HvzAF=w489-h867-no)

Will be keeping them though, they're not damaged and I think they suit the bike to keep it looking stock.  Would like to keep it as original as I can to be honest, just change anything worn out or consumable.
Title: Re: Nogs FJ Restoration Project
Post by: celticbiker on 21:08 - 21 May, 2019

Would like to keep it as original as I can to be honest, just change anything worn out or consumable.

Does that include the owner?

Sent from my SM-G950F using Tapatalk
Title: Re: Nogs FJ Restoration Project
Post by: Rob the Nog on 21:15 - 21 May, 2019
Plenty worn out but unfortunately not replaceable :(
Title: Re: Nogs FJ Restoration Project
Post by: Readmarx on 22:09 - 21 May, 2019
You have a dwarf doing your rebuild then?
Title: Re: Nogs FJ Restoration Project
Post by: AlunL on 06:16 - 22 May, 2019
You have a dwarf doing your rebuild then?
Nah, that’s either Jeremy Beadle’s left hand or either one of Trumps...
Title: Re: Nogs FJ Restoration Project
Post by: Rob the Nog on 09:51 - 22 May, 2019
Lol, that's why I thought I'd take the picture, couldn't believe the size when you have them in your mitts.

Have ordered a bag of soda and will give the blasting a go - if it works ok will do the engine with it too as getting into the fins will be a right PITA.

If it doesn't work I have a lot of cakes to make to use it all up.
Title: Re: Nogs FJ Restoration Project
Post by: Rob the Nog on 08:25 - 2 July, 2019
Started getting back to the FJ now the ZRX is finally sorted.

Started stripping the flaking paint from the valve cover and looking the rest of the engine over to see what's the best way to attack it.

It's tricky, the valve cover is easy, most of the paint is off now and will be easy enough to prep for a spray of engine paint, but the fins and casing's are a bit more difficult.

I'm not trying to make the bike look like it's come out of a showroom, just that it's in nice condition, so I think a degrease and jet wash to blast any loose paint off should be ok for the fins.  I can then work around the casings (remove where needed) tidying them up for re-spraying here and there.  A lot of the engine simply needs cleaning more than anything.  I reckon it's going to be a slow process but will start working my way around it.
Title: Re: Nogs FJ Restoration Project
Post by: CoxyLaad on 09:52 - 2 July, 2019
just as a bit of inspiration, there was a guy on the track with an FJ last thursday. He clearly races it in some series, you could just tell with the way it had been modified, and the number board on the front.
Title: Re: Nogs FJ Restoration Project
Post by: AlunL on 09:05 - 3 July, 2019
just as a bit of inspiration, there was a guy on the track with an FJ last thursday. He clearly races it in some series, you could just tell with the way it had been modified, and the number board on the front.
There’s a guy in Gloucestershire called Doc who runs the FJ club. He builds and races FJ1100s which can (allegedly) keep up with many modern sportsbikes.
Title: Re: Nogs FJ Restoration Project
Post by: Rob the Nog on 09:16 - 3 July, 2019
Moved the engine outside ready for spraying in engine degreaser.

(https://lh3.googleusercontent.com/-KaCPEMaZZ_KkYW0o8MdFXBEsk_b8doTe9atto2BRFrl81JmMOf2EjLVwabrX9o4yzCGB2kTdrNISnDjnYkofA3RNj9tGKH113vZHyQOooHlj-DcjZLHftR8dEZvomVQt1hB0PQyuc9UXyaI-mvAI5-3RiR_LUmEk9cvlpXDnRX4R4tC0B0F1rZpDnYlNr902GsT9jM4hsTGVeyXHkXgxXHZpbhsCWOU5YCT735Bk4XWEynPPjm4sKDPQU-EaumdX_NHcj8eNaY-QkZUUK87bxfMnUlqGhE9ca9KZwx8vYenXNe4FVgq7-kJwlNpZ7RegNolgCqoa45eA_NhqNdHke19N0pP78qJiwbwbMmxMYFM6AG6Zhl8I5GT9kDiluTtPmILNb0MhGSN-qYRZKFupDNvHqVX2eKEbSMRqKPx4D39gEyGCjqfd1ZVYI0F5PCTWzK4PjT2ijov_MVSLzwL-ebJJNtYyPRtXDiNJWU3Ma7QIKol6-XhFGLhkBti9XFy9Cl3Xfxvsk7OlX8FRb3sKByvmHSg_UBChRuaBKp1WzG82AQboNBvNiqbsrdljMeHoURDCQuWia86qLd-eZRV9taMppN_eifm7cucRL6QcY8gaIrlfFqKHuR52j0PBw_C_KdkUfGvJbogBgDsDpCXhUmcqKS06XcsL12kVI7y1sa3Q_WPOmiEL3JY1twritPcaFlJUwmI4AfzM_1-V8Vy3bp-=w1632-h918-no)

After a good soak, hosed off the degreaser and then soaked again in some SurfEx stuff which is good at getting oily crap off.  Jet washed (carefully) and blasted out the fins etc.

Moved back in to dry off over the next day or two:

(https://lh3.googleusercontent.com/gmgCLxtgcwVBJ52WzDsmm_2ovP2-rOQxPuCvUYksUnaOxjXkLasyfz-450IzJtQW6MiVffWdCixCz5BnDI9dwa3WJVYWZUHro2PM0F8uZwuhEMLMno1L_GRnX4eOZSAZJNJnwMij0AXA47vZ468Faw1tEGWb8M3tq_LqNn_OPoO0YxBEqr4fHTq2yZYvBAQkkxzZsydeuvfLS9FxNw6N1HSIXCnzAQ_ITP9DyMtmWGts-_LtSIK0_U0tCjx8_zd7fks8-l4Wkne4jUNcTJpA6XunRHfOJBzO9yR9qQLBcRqgMP3LdwBce9Z6QOWCdxE-6csryq3TPhyapp9Yfzzn1VyWLCMMj5DhtGLKbBi54ywwlSl0Q4TKBPNP2teBXaPWKcKUV4Aik2J8nL4_h2bOuc5mokyIyHDkEQ5b4IAfH5Z54JdyORw8pkXB4Ml01VdqADE1muCH2sjbTQuPxwDGQg_GQOypLJvgq1R-RCsyUmApkbFDOK04qvylmjU2xnPEmh-MtHA5RuWgIbD57e-ajRvoF_U_7-ZvfPSR0gI88sQpa9UppyzIrgUBbXknESd9RHU5x50ZzHmjCY4fVqfAzakciCs6b5r9_tss5ClUTravzvLIjsyjbAV9szPNN2CoE1yi_lSKis70yaqQExjUwbVdzGWEDcDyo5m28rnSSLVPTJszBiVPhst1_iOOUmWfn8Ra6z3p1-JNEk0hsfWfJ_WG=w1632-h918-no)

It seems to have blasted off the loose paint quite nicely.  I'll spray everywhere with brake cleaner once dry to thoroughly get any remaining grease etc out of the fins etc and then can look at giving a few coats of black engine enamel.
Title: Re: Nogs FJ Restoration Project
Post by: CoxyLaad on 21:03 - 4 July, 2019
Good work. Its rewarding but doesnt half make a mess doesnt it!
Title: Re: Nogs FJ Restoration Project
Post by: Readmarx on 22:56 - 4 July, 2019
That motor is a proper old beast  :afro
Title: Re: Nogs FJ Restoration Project
Post by: Rob the Nog on 14:06 - 7 July, 2019
That motor is a proper old beast  :afro

Yeah it's a right old lump to manhandle around :)  Should be a fun day that goes back in the frame.

Managed to do more work on it this weekend.  Got the surface prepped for painting.

(https://lh3.googleusercontent.com/iFHoErfHGIiwZQlQ-SYI9oERabpcKSbsxzQLfw8Zw0-bZlAXO2oFjTKtAl-O7nKjexFXqevir3PjJsWC_Ul3E7nvgLjRePCWs5PLQxi3g2z-hLdUF2R9xlbesKslLADikF2_fJidSRdoK3vQKW_m787tzrJgMHOSiEmXBusjoEAowu6qo-0u3kbI71OJCq36A2nSrfA4CvCol6pQbxGBDwoS9WtEv-6Nsr3TVbBzaGebwt8EMyNr2I5kya1IRw2m0-I2G2A4x2o0t3MHZULMU7zw5Cg5HdB5w36q8ny_qX3e4--GlUesa8IvGt8wbJE-yNhSa7kdr6TD4XmvVJ4A6pfuDOUBR9GExRhnxiQfEfh5SExd-50Die_vw6JyLWboyNhkR3mahmFcYUWx0s5oejXuCcpL689zVLy1niVc86kWe_6AG85X43XMtEkMVriU5Gi2DgKV4Rg0gzqvWGDP2PanU5qi4gbPFfisnVcEO39eKU5JR-HMq2sqh4fFTojawcH6qWLv2J9wtsRuqyin0BZ18tPxg7e3BjRlwv9ltq1LXJL8sbPoiQXSVfxiHaI1-yGgct5Bnxxr7WKqidUc9zFYlUY3Ld3qo14UgRbBf9IZfy0tWYbKdlP_6KH4pTA_LfIjqfTLan4_j5nON1SwXVPjlVLBy-s=w1157-h867-no)

The two left inlets are still on just for this picture to remind me which side has a bracket top and bottom (right one only has an upper bracket).

Quick mist coat and then around 3-4 good coats of engine enamel.

(https://lh3.googleusercontent.com/LEFOpPLvH8IcOsvVGEi5-uL9DLbTRJNPObPe9bYocgSpEtKGlQidSvag7CjlxTjpV_C58ivJQPu0XdK28RJxmlpiYzX0kQHYZ6SFmpvxTIcL1kn6viAGBVPIDF4LJ8erfaWZMm8nFTrr47tqOg8Rp1TR1GT0oECHjUJ_5ZrtVpedCf0S-cz8niScoXtnOauCWbe5P-oN-bmsBmgGMeZcFtFbzWdgB1rK3ygJReJPbQ98Q4BCzRELZzNIQNIBWGuZ8ahk-IWGNaKDOn3deiU1vpvcbeMilHw4UhtZrU0jmhClbvaIVyY6_u9-JJouUvxnh6QhR54gnh_vF5ly32mTfjdnHceSt7J79U0HfwXPruYhWn770ySwyN4wlLdohqIp5gq7zxbMkPBykawLpKrnzg1lwfepdFTR0SStnxNQeaCMGrLJ10WrCvWWlE0nkgJFw8Xe1d__YSdD3yNbsg910wT55oRNDcvTrn4F2P_bjlDvpITZ9p1rdwjoWyGpVHWPUhsEuJ9IApkundllv4ugqgD0MuSjtEB9x2HN0RIV5UO1ELsTwAYmsI2MCM3tIa3CT_IfNn9-uKxpvq2-GMUT-rn2GxAHQlVn9oPkGLy5UV-rmhMvU5KNBAMTMNgYmSLUd5B-HZ2nGRUgx7ReMPoIHV4XyzkhhF2iGrMYH_abpAEAdiwDDJmsXUwbRrxGGSz_zbmXOK_j-R5qjuXP_kUpvZ6N=w1157-h867-no)

Have removed the tape today but will give it a week to fully cure before I tidy up the bare side cases with the yamaha logo.  Quite pleased with the job.  The engine is mainly hidden behind fairings but nice to know it's all fully sorted.  Also took the starter motor out and cleaned and repainted that too.

Will post up a pic once the all back together and tarted up :)
Title: Re: Nogs FJ Restoration Project
Post by: Rob the Nog on 20:27 - 27 July, 2019
Had a bit of a nightmare getting the engine back in and the heat and humidity didn't help sweating away in the garage.

The problem was lining up the mounts with the frame, once the top rear one went in had to wangle it around to finally get the bottom rear mount through.

Finally managed it all and the engines sitting nicely back in the frame now.

New carb inlets fitted before getting it back in:

(https://lh3.googleusercontent.com/HubUiMhv8-d6LP4T68C-s4e1M01WgyOM-NJzpYHGkLWkIgD7TOhn-EM9VnSZ5_mrH1daYoIK9bneBj_FLTu6-xkpNEjqyzo8wwOpSMyTgfOjDPuLXvzhCdALU5cWOwucIBcPZyBemGFaVuQbu2IBPQP2MpbfX1Dwi4mN8qd-xR8LKr6gIZe8nyRsZppW7jfzLjK2Xc8-rbiXvTrTSqvu6veTXeKtpfhxLiZOQsEOPjJCVZ_KaM5UE5FbX8yZ7PTsUp3ONTnxS8KM7l10a_3Puu1rL_UueGo6RG4IYqojT0REBQnMDXzD_SYqk5dOqa0pefxmwiKuC-loDmZqrP4P2CLnIRPR7r1DNMzJXMoLYFuGmlL3I70DitH8tGLdhyymP0Znw5Mv7sGOYWVfh5NZha-pjrt0edKk9l-MyE3Ykm-2w5pfzzKF9vKEgaq9tN7paLAuIKPjQxzX-fP4quw8iN_G3UmbrHmYvp6NkLVr6gZUeoRjJdrjc0I6hPQLpXyuO_e_IS6ExcwkeKxxeVMJ3xxUi08O6PGR92opWZk8ePuVcheQN7MiI4bwnaDH9-BLS5Nso0j1XSqHw0nUxabZWOwc3e6NGcWSEEXfCnDpXg67xUPMuDICB-nyo0FIFkNfwOw3mrdxodau3ZhMYJjWsZ6aQEKXdhpikjPVxDTNkgXMty0gfxz0vDiZEeiHhjsYEKiQNdiku8-XCzAVwtl9oJMX=w1157-h867-no)

(https://lh3.googleusercontent.com/EpyoDxC41evDPvDcnMCo9-P7LKJuxfer4YqKbtFHBYud1shV2Uu5ZdxwDwJS2IjqsxPkHGebhbzX_RHy9fN0gwWMJwJK08361AsY3yTWsw1ozlkHR19ftPt15dDNzW-BoEM7PaYK6LAuxclJ2P_Bl7zhELrygalWwW9v0PwmZpQLGf_e9mrnAXjLYcmXoX7SRwLgzCAJA2HNiAdzSPh-KqCARcIBtwJ3fC2pvB2UiVYbTXVu3fgjqM_M2dUJDb4kmsTChRx2GceRawfVKs-vb2s0-jWuNtipPR6N_cVQhpLA4mHWw26TkPmxwl9ACc8oVnqsKQia0H3nALUBrFsw5WWbRIkvXzcOqvnXAD8qChb_sRUHOAHmi0EsKI_LDYohoNUF0tMdNWzKvKdjGcyqHqIhwhUK_x0kHbKs0niNlT2UXnnA8ny9Bi8m1O_CnkRlLFbB8qEDAc8j4PIQQLv3-Aqg7ImAUOUgnPNFIEAJLZ4hV11xoLURtJORKkTe3PTXdd0ppwAJ3H5ow555Sx2fVK7tOJXiDQp8cYxR8hVIlSnajUtowUET9ay3cnRbjDIee-BtXjVQBSb_x6jL0XWvUdl3Q_nkfgHmt1bxMIvd4uNYyobY4sfXhTct5gakENK910Lqe109J2fIwNnMo8W6-ceOWMW4XjifESqYOT_SjnvkZ3dP2rt1k-Ve48t5zwx58dPqXUieOf6t5lKAvDbyVJ5Y=w1157-h867-no)

The front mounting bracket was just to line the engine up, but it's now hanging from the garage roof with a nice coat of fresh paint.

Will get the front mounts fitted then and can start putting the loom back in.
Title: Re: Nogs FJ Restoration Project
Post by: CoxyLaad on 22:58 - 27 July, 2019
This is going to be ace :)
Title: Re: Nogs FJ Restoration Project
Post by: Readmarx on 23:07 - 27 July, 2019
Looking good, Rob. Are you resisting any temptation to paint or replace parts because they don't look as good against the frame and engine?

The RSV (ate 4 engines) needed the engine rotating slightly when it's back end was within the frame to then get the front engine mounts to align and fit spacers before you could insert the rear and front mounting bolts. You needed to be an octopus and build like Schwarzenegger - ba :censored rd  of a job!
Title: Re: Nogs FJ Restoration Project
Post by: Rob the Nog on 08:52 - 28 July, 2019
Yeah I'll paint anything that needs it, if it looks out of place now I guess.

I'll only replace if the part is knackered or would benefit from it.

The plastics are going to be the hard part.  I've got a plan in mind how to rebuild the missing lugs, patch the gaps and cracks and then re-spray, but I think that aspect may be the make or break aspect, as decent plastics for these are hard to come by and hugely expensive.
Title: Re: Nogs FJ Restoration Project
Post by: Rob the Nog on 15:44 - 28 July, 2019
Started laying the loom back out on the frame. Am stripping back the old crappy tape as it's obviously been repaired and bits added in places. Wiring looks ok underneath without too many surprises so at least that's a bonus.

Must admit, it's at this point I do wish I'd took more photos. Thought I'd taken loads but a tip for doing this again is you can never take enough photos when stripping it.
Title: Re: Nogs FJ Restoration Project
Post by: Vu Ja Dave on 00:20 - 29 July, 2019
I've been doing more 'n' more plastic 'welding' as bits break. I use a soldering iron and add in a similar plastic if needed. Try not to breath the fumes.
Title: Re: Nogs FJ Restoration Project
Post by: BashplateAlAssad on 09:58 - 29 July, 2019
I did try the heating/filler for plastic replacement but I think you nailed it there Dave, the fumes are pig awful. I ended up using plumbers plastic pipe glue and supporting pits, it seemed to meld really well. Plus the woozy feeling of breathing all that glue is much better than coughing a nut up.
Title: Re: Nogs FJ Restoration Project
Post by: Rob the Nog on 10:13 - 29 July, 2019
Plastic welding works great on modern fairings, but the older stuff can be a bit brittle and difficult to do apparently.

On the FJ forum they came up with using pipe weld solvent to repair them.  I have some anyway and tried a small piece of plastic drain pipe (which the solvent is designed for) on the back of a panel and it bonded really well.

What I've got in mind is getting some black square guttering and cutting it to make small lugs and filler panels that I can bond in with the solvent.  The square guttering has a nice mix of flat section for filler panels and bends for making lugs/brackets.  I might give plastic welding a go as well and see if it takes, maybe as extra strengthening.

Once all done I should be ok to sand it back and then re-spray it all.  That's the plan anyway, it's just a bit of an idea at the moment so will see how it goes in practice.
Title: Re: Nogs FJ Restoration Project
Post by: BashplateAlAssad on 14:37 - 30 July, 2019
Sounds like a cunning plan.
Title: Re: Nogs FJ Restoration Project
Post by: E.T. on 19:11 - 30 July, 2019
 :eat
Title: Re: Nogs FJ Restoration Project
Post by: CoxyLaad on 10:10 - 1 August, 2019
Started laying the loom back out on the frame. Am stripping back the old crappy tape as it's obviously been repaired and bits added in places. Wiring looks ok underneath without too many surprises so at least that's a bonus.

Must admit, it's at this point I do wish I'd took more photos. Thought I'd taken loads but a tip for doing this again is you can never take enough photos when stripping it.

are you using self amalgamating tape? its good stuff, flexible, and once its wrapped it err,.. self amalgamates into into self leaving no joins.
Title: Re: Nogs FJ Restoration Project
Post by: Rob the Nog on 10:20 - 1 August, 2019
Nah just good old insulation tape.  I use SA tape where water might get in or there's maybe more potential for the heat to melt the insulation tape.  I might put the odd bit here and there along the loom to bind the insulation tape firmly but in the cooler area's around the headstock etc insulation tape is usually fine.

Also SA tape is bloody expensive compared to cheapo insulation tape and I'm a tight git  ;)
Title: Re: Nogs FJ Restoration Project
Post by: CoxyLaad on 14:49 - 1 August, 2019
you can get it from screwfix pretty cheaply.

SA tape is a lot more flexibly than insulating tape when its bound up, it makes fitting everything a bit easier.

my entire loomed is wrapped in the stuff
Title: Re: Nogs FJ Restoration Project
Post by: BashplateAlAssad on 15:07 - 1 August, 2019
You have to be careful with SA tape, if you put it on something that is going to take a fair bit of rubbing (snarf) then it will wear through quite easily, so be careful around the headstock area.
Title: Re: Nogs FJ Restoration Project
Post by: E.T. on 17:53 - 1 August, 2019
Also make sure nothing can get in... capillary action say... Cos it won't drain out again so corrosion if it's around anything corrrrrodable.



Do it properly and it's good. And stick something harder over it if it's chaffing.   :confused:
Title: Re: Nogs FJ Restoration Project
Post by: Rob the Nog on 08:39 - 2 August, 2019
Have been tarting up a few bits and bobs, no pictures but have painted the top yolk and also sorted the centre stand.

It was pretty grim with lots of surface rust etc, cleaned it all up to check it was structurally ok and the only issue was the 'feet' where they had worn a bit thin and were looking like the metal was cracking and had been dented inwards.  I've filled and built up a layer of weld over the feet and then smoothed it back flat with the grinder, so hopefully there should be plenty of life left.  A good blast with brake cleaner and now it's hanging in the garage with a nice coat of black paint.
Title: Re: Nogs FJ Restoration Project
Post by: Zippy on 09:12 - 2 August, 2019
Anything with surface rust, I tend to paint with a layer of rust neutraliser (BH hydrate 80, vactan etc.) before then painting for good. Just gives a bit more lifespan I find.

(https://live.staticflickr.com/8265/29950181595_ab36276ddf_z.jpg) (https://flic.kr/p/MCAvxi)
02-brackets (https://flic.kr/p/MCAvxi) by Chris Reeves (https://www.flickr.com/photos/zippyonline/), on Flickr
Title: Re: Nogs FJ Restoration Project
Post by: Rob the Nog on 08:44 - 12 August, 2019
Been a bit quiet as I've just been doing loads of prep work on a few things in the background.

Been cleaning up the headlight subframe and given a fresh coat of paint, fitted clocks and headlight and looking ok.

(https://lh3.googleusercontent.com/5iCPernjpewKWX3RJ7YqYvgVJtsrUL0PhXSABAK2ScaOWKALJiaUz7QYhpEjgHi2RGtQjVI9k8BjfrUgC6_8JQSYkU7G0LP0HDZLAF5KfMzSP4-b6MclTrYOt27lZwCp-BdqmUfK3KsluaMDcxceimUrgMdW7UeCsyHG2-JS81LXGJHIYn-E4jE4Ai1BgC24JaB7r-0AOBmydCBqUN5y7BJj7bYHbmHgtB0amTiaQ_gjGK4bpF0bR7A2YqMq-R79yaT0DP1_Dw5Bx5VWBrJm-9iZVo2PuR4edUXvWkTTNgp_RJ7IzExxkcjRcr46a6rhcfAALV9BR36IW3vYSh9V7S47Z64oz20mpyuXpzzof8EKYsNOYIiZbPQhrnr4g6psucygCZ9Sjc0SVWbyvk9uYkIjidEGaSsg_B530BUf0iNcuirIeYf3iDLnsmzXMPXn7j8U-TFTVWYFllkxSCSJL-Z8R9bAG4UdpGj0JY8qJpMZzxjxsTNqp7pxsyZc2bw15aP-SlpbSyRz8twC8dMoSaAJ0Bi-esFs93S33mxD4TyIaFSHbJMDePAAWkKowi0diO-hSpnOviCZCigcz9O48_iiIloYGOX7wqNxJiz2TK6eBXTjBDIdZqjGlyGt5_MhgOUhQ4UvNGg5B5WJgPqT-0nL_sf9QSM4O5HIbV3jI-KEQ84jt5aQNYYAv25u1Gym7GTHwhiYuAp5Gc6o8BSJBFaJ=w1224-h918-no)

(https://lh3.googleusercontent.com/k242lSGQeAlkHIeo9DvE9kLtQSyrD7nuzgXhVo_qg6sx6gdUJegNXhFe-WP0wgRFQKsKAgHsiSdzRZzRM48QLXW1-RMVEceTBgekdTBolHOLH43351x-WqgDNFhw_V0rcOSDfZxPsEIDqfV-pO44cvhyFQLynEDL5igYO__v7VrlxUFUBpv0VKCZ_z4ksXNMbvG0kjVoek5TOb2kZzV2A3J_v3D44UKfVvxYOVrGsWHol58ABGjmFwQw87qkw4GwBNDI-qU_yZ2Pw6m75FqUfQGsvvNDfay7krr6lkxzQXZ1TgS2gL-yuZMtdvVL-nxJ1dKzgIBYUmcdX7T0hjpBXR4JZjqEGdNxnhtRFXQpV5G04gcT7qIVqeOabYMlrqi7vbyncmJ8WYl20gMCMfmVmo-D69uh1S5lA3RO77b5FFfMu1jOWZYQHYN0BoJUNGxZbivpHmvqAkuA7I6knQDjCOeBuua6PAHKFnVEjUsV1kJoOBYxrmMGfegEzj8JIbHFddpN9kgHDIkq-yeaJTWLffDQo9Oc5tkpWY30lxl1JTaxCpLLoDyI3cIiXr0ms_LtDlXNHEL51QCiyFWk55b4SfLUS5E23TLCgxV2IcPHIElgCVE_EirhTlcrLUAZAjf18RcZeAKnlrfiPYVfj0J7NpChxrGI2FAU8eP7D-nzIiDF56JLFpN1-4-BeECeOxRtXwtl0lpk-EYtz2cTXB_Uyt41=w1224-h918-no)

Also had to rewire the clocks - as the speedo was kaput, I got some XJ900 clocks which are essentially the same, but as they're off a slightly newer model (with digital clock no less), the wiring is slightly different. 

(https://lh3.googleusercontent.com/PDnuffyrL67CBBkrxqcbgxruFwIDr-eI8--FrHWzEGkXHscJA8teSbl1vefkZ5UwxhYMvboevwMVtkYla9AoGQkd042wwQVgB1K9SE57lUIDX0emA2StNXEIRSPecgycGCpKRSrw7aVnPYZB7cM4ONW5YRNTCnOyXA-Wsr1xh8UB-o1TKN83Jvdj6x8Eau6TSXfoQStoRSAT7Rckro6V6glLTCyxiDgRX-HFjyyPTIp_bhM8xUT8pGRPl5-8WilTKWOgO_zWpWxD3TtkfP04qE1-icmABQij1kPMWYDJ8U2WZZIOXsDN7Gv2U7EdKuHSHIe5uLJSS3h3FdhzX6D7MEDOk1jYkUWC5qe5DTk6LG0oS3yRzjH1K1DRTHZYKsTNxqfqmyUA1Kr8H5CWhE_-ITPhmjYeGKOvTSEgsjEXvVWNHZgKmRwbadODukCQXbUrClPcrDAyMemvLDKPMTWaxR6lpdq6OW-zwJdlEjjxZK63HD1Cxg2AX7oGuOdEUcPxgXJdBvReGdeWO3fFG0rolIKp8oq6scmfN3uPmOhbaCw1MiSq2RrSxj-5zeN_DnW-ey_RwkPM2OKpVPyuFH5cw7cM50eqTw4BhrcRGGW3CcunUEBqDSibwGoWc1CxjXs9crL4VXQ4ZWh_hZZ0ltoivY5yk6dl237g7roC6D9KerW68EMfxlJIjBdEx9UTiUkAQxGSF72wM9FdlFuC6RPZnvBC=w1224-h918-no)

The bulk of it is the same and should work ok, however in my original clocks there's 4 wires going to a little PCB in the housing.  This isn't present in the newer clocks, and not sure what this does, so have winged it a little and took the PCB out and wired the 4 wires to it so at least it follows the original wiring and will see what happens.  Worst case is I reuse the original clocks again and simply pop the XJ speedo mechanism in that one.  Have a spare live already for the clock so fingers crossed it should all work ok.

Have been tidying up the rear subframe, removing rust and loose paint, and will hopefully get around to paint that this week too and can start re-building the bike.

It's starting to feel like it's coming together but just got to stay patient and not rush anything as a long way to go yet, especially when i get to fixing the fairings.  I'm hoping in the coming month or so that I can have the carbs back on and at least give it a test run to make sure the engine and wiring is all working as it should before starting to work on the rest.
Title: Re: Nogs FJ Restoration Project
Post by: CoxyLaad on 08:57 - 12 August, 2019
look at the size of those clocks!!
Title: Re: Nogs FJ Restoration Project
Post by: Rob the Nog on 09:37 - 12 August, 2019
Lol, it's to counter balance the rear indicators.
Title: Re: Nogs FJ Restoration Project
Post by: E.T. on 19:23 - 12 August, 2019
Proper instruments. None of that digicrap stuff  :thumb
Title: Re: Nogs FJ Restoration Project
Post by: Readmarx on 21:13 - 12 August, 2019
Yup, good to get it up and running before you sort the bodywork. If you can just run it and then ride it for a simple 30 mile round trip with the tank and seat on it. Bit of urban and bit of A road to check it's all fluid tight, fuelling well, electrically ok and all nuts, bolts and steering are sorted so you can tweak and sort without messing with bodywork

Title: Re: Nogs FJ Restoration Project
Post by: Rob the Nog on 08:40 - 9 September, 2019
Made some good progress over the weekend.

Had the rear subframe re-painted and drying all week and fitted on Saturday, put all the battery tray and plastics back and wired the loom back into place.

(https://lh3.googleusercontent.com/GROwI6RXRfFNbkj43i5MSOI2oQXW77eow_qAOc1vNPIH2Ko0qS5TEhywn3xuPtpVT5cdRlQwCr3tUb9Km3qBtqbMtBBDyi1QXI9XDZlgnX0V_gzFW84EJRdvfxEYubafLbGbofA0Hc6SntQ_W81m7mV2rBxmsvoB6juZUnXgkoj4NLaXHib3sapi-xiwasBiZPGdHE5vkqVMsQipBQagclEQqQCaTBA25wOMpbZUNY1bk8076Ret-u_9R9BjRssdd6I9db7LPcQWbcpq-pbYd3bVksXY4SpNi2AHk_NKNeDmq9kht8qaJ2qk1QufQuJat3Vf7PwOJEAdev0-zd-NK8HOyWBe-2KCDWpuzBNa_LPBB_i3k00GzFNtGdV3SR93-2RfFO78vFR0rK3o2Ir3KjWBq7DOP6FKiERX09ptZ0TY_bWKd47LdrDAEBNU2QPG-FbKGMIwbp7cMFoGICtQOfvDaNHYtjx4JFiXQBm6Jod65ffKT_KcQLuEpstSZmsY7wmjvKkBOqE5Yt6Yad-s48rWqqrHkjmwliYj9JwRWQT_xlXINZ8luMSCzIdCG4PVwvDtFt7KlyO3gblRKle99MECFfyU9uDx4we0_nb37XVIgxmrUZWoc8AyNfd4uFxEHYMQnw2fE2oYp1w_hOrgMmLSJHo-2GOucXMgoV24VGRg3al9qy4BUKdRqCV_5D_VPtb2G-sQIPCo9UHzyUQwACp_ESzwxlGY1w-auQDN4M_jDevx=w1224-h918-no)

(hope the picture works)

Had a slight delay in trying to find why I had a left over connector and after spending longer than I wanted checking the wiring diagram, realised I'd forgotten to put the sidestand sensor back on the bike (since the sidestand isn't back on yet)  :bag

Plugged it in and all looked good.  Stood back and realised that if I get the carbs sorted, I'm not far from a quick test fire just to make sure everythings working as expected before I go any farther in rebuilding it.

Carbs sorted and back on, oil in the engine and battery charged.

Fired instantly which shocked me (in a good way) but then my leg got covered in oil when I noticed a missing bleed screw in the oil filter housing - stopped the bike and sorted it.  Fired back up and more oil over my leg as the clutch rod shot out - since it's a hydraulic clutch and I hadn't put the piston housing back on, the rod was free to pop out from oil pressure.  Another quick stop, put the piston on and lets try again.

All working nicely and now holding oil where it's supposed to be.  The headers haven't been put on with any accuracy as they'll be coming off again so there's a little blow from them making some noise, but overall the engine seems to sound and run nicely, at least for a quick and dirty test run.

https://youtu.be/lZ0Q1gcc9jQ

It was tricky holding the camera and operating the carbs without choke and accelerator cables attached, so it eventually cut out, but you get the idea.

I noticed the rev counter wasn't working, so either I need to check the wiring, or the XJ900 clocks I got aren't as compatible as I'd been led to believe.  Either way, I bought them purely as the speedo in the original clocks isn't working and the worst case is I go back to the old clocks and just swap the speedo out.  Since it's mechanical I'm hoping there shouldn't be an issue with this.

Also noticed whoever bought the silencers must have gone for some cheapo items on ebay and just winged it, as they don't properly fit the link pipes - they have a wider internal diameter and they've used a lot of exhaust wrap to fill the gap.  The cans are Viper and decent enough, but I might have a go at making some collars or something to fit over the link pipes and bridge the gap.  I'm sure I can sort something better than filling with wrap.

Anyway, so far so good - now I can work on getting the bike mechanically rebuilt and then it's ready to begin the plastic repairs  :thumb
Title: Re: Nogs FJ Restoration Project
Post by: Rob the Nog on 08:20 - 20 September, 2019
Not much to write about at the moment.

Have re-wired the old clocks back in but with the XJ speedo, so hopefully that will all work ok - shame I couldn't get the entire clocks to work with the digital clock, no big deal but would be a nice touch with the newer clocks.

Aside from that have just been getting all the little bits and pieces tidied up - painted the clutch piston housing and the front brake reservoir etc, all just tarting up stuff now before I torque all the frame mounts etc up to spec and then can start the cosmetic work to the fuel tank and plastics.  Shame we're getting into the cooler weather for when I'll be starting to paint, but it simply slows down the process rather than stops it.
Title: Re: Nogs FJ Restoration Project
Post by: Readmarx on 23:52 - 21 September, 2019
All those little jobs to check and sort all sorts of things to ensure reliability are worth their weight and wait
Title: Re: Nogs FJ Restoration Project
Post by: Rob the Nog on 15:49 - 26 September, 2019
Come down with a bloody dose of Manthrax, so updates will be quiet for a while as not feeling the attraction of the garage, especially with the weather turning this week :sad

Hopefully will get back into it after the weekend.
Title: Re: Nogs FJ Restoration Project
Post by: AlunL on 16:47 - 26 September, 2019
Use it as ‘thinking & planning’ time. Get some old copies of classic mechanics or practical sportsbike to browse.
Title: Re: Nogs FJ Restoration Project
Post by: AlunL on 16:51 - 26 September, 2019
https://youtu.be/VbmbMSrsZVQ
Title: Re: Nogs FJ Restoration Project
Post by: E.T. on 17:25 - 26 September, 2019
Use it as ‘thinking & planning’ time. Get some old copies of classic mechanics or practical sportsbike to browse.
or Playboy
Title: Re: Nogs FJ Restoration Project
Post by: Readmarx on 21:35 - 26 September, 2019
Use it as ‘thinking & planning’ time. Get some old copies of classic mechanics or practical sportsbike to browse.
or Leather Joy boys

 :shock
Title: Re: Nogs FJ Restoration Project
Post by: CoxyLaad on 11:23 - 27 September, 2019
i do love a first startup clip!
Title: Re: Nogs FJ Restoration Project
Post by: Rob the Nog on 15:33 - 11 October, 2019
Stripped the brake calipers apart last week ready for an overhaul with all new seals and pads.

Unfortunately as they've been left dry off the bike for so long, the pistons are stuck in the seals and I'd split the calipers before I'd realised.

Couldn't be bothered putting them back together to try and pump fluid through as the MC was also stripped down being re-painted, so took the opportunity to order more bike tools and got a set of piston pullers (just a chinesium cheap set).  The pistons are 34mm but these only go up to 30mm, so will be knocking up some spacers to bridge the gap.

Once out should be a simply clean up, new seals in and then can fit back on the bike with the new pads.
Title: Re: Nogs FJ Restoration Project
Post by: Zippy on 15:50 - 11 October, 2019
Couldn't be bothered putting them back together to try and pump fluid through

You got an air compressor?
Title: Re: Nogs FJ Restoration Project
Post by: Rob the Nog on 18:06 - 11 October, 2019
Yeah, too many holes to fill, as the actress said to the bishop.
Title: Re: Nogs FJ Restoration Project
Post by: Rob the Nog on 08:43 - 14 October, 2019
Piston puller arrived.  As I say it's a cheapo thing that will be simply occasional use, so not a big deal, and as with all these cheap kits the largest size they go to is 30mm, the FJ has 36mm pistons, so I was already primed to make myself the extra bit needed.

Turned out a section of aluminium and cut some slots in to allow the tool to spread it wide (ooer missus).

(https://lh3.googleusercontent.com/UEBfyx-wsZUjXhh5MMfrQQ1ZifV_-V-HTrfDZvPqp3j4lXI4P9Uui63uhFPuEv5nL7XMd4024BXV0_WDCWTw3KzFmVnfL6uF7wY8PIO_I6Ydcidpf0lahUB51kozcSsPRX263ACqL7twZnoG2W4mGpA5muJ1FjRDuqFu3CfFjiZ-vjniGZ-Nsept5QwabXk3rw-XBhhdjrcCdN_cAYovhsY4dayof5qr8R-izGIj3qqjQ4WLBJG1eMYG5oCu9wu3g-_y7Bl4KElvuRpnCSbDdSTcIhKUn12NS3ekSMP2Wi9kfqiMgp0Bra2kMkGm7zgyKyqkFSd8VK-BOS27s0yC9wVjBXqLGCUOK_Lp05L8ozKmJeL4TR5ldzSPHEWdIVHcwXM_zreCw7adfBVt-9Gq5WjfhS9tssQkif4lm6qK8aNn9jZUV9BiPnQKlPXsN7eQav0EjBoVOzdE-ggB9LWJPFKAciOCCbb7aQ1neyC0gIkLJ6lhBt6fqT4SPJiZge5UaS1PidmWtxBl2POncz2CnRD08v-gKOSCXIWNhXNdmkG8l7L2EKSnYcoKzjn4Sti6US-MZBVe3Jl3fufRgiByp8itr5BeJSYuzJ2-aP9Q-zoYxpZSUamST5PTX7nGpK0kiEupnsR9qC-lUPDzxonYZD8j_eMwMFODnPgg3cE_QHuLspaeQ_u7zeY=w1219-h914-no)

I could have easily made something to do the job, but as I say, these Chinese things are so cheap it would probably cost me more in the parts and time to knock something together.  It's also fairly basic so not much to go wrong, so I reckon will last for the use I will ever need from it.

The slide hammer still wouldn't actually budge the pistons so an alternative is to put the tool in the vice and then rotate the caliper itself to break the seal and get it to rotate up off the piston.  Lots of grunting later and the pistons were out.

Cleaned, up, and new seals back in it's all ready to go back on the bike  :thumb
Title: Re: Nogs FJ Restoration Project
Post by: Readmarx on 23:08 - 14 October, 2019
Lovely. I hate jobs like that. But once done (and especially something safety critical like brakes) the satisfaction and peace of mind is a great feeling
Title: Re: Nogs FJ Restoration Project
Post by: Rob the Nog on 07:57 - 15 October, 2019
Yeah it's one of the area's I always like to service on a 'new' (old) bike.  Get the brakes up to snuff along with oil/filters as a minimum.
Title: Re: Nogs FJ Restoration Project
Post by: Readmarx on 19:16 - 16 October, 2019
Remind me what you're doing with it's suspenders?
Title: Re: Nogs FJ Restoration Project
Post by: Rob the Nog on 20:03 - 16 October, 2019
Not much. Rear shock looks decent to be honest.

Front has new oil and seals and anti-dive is blocked off.
Title: Re: Nogs FJ Restoration Project
Post by: AlunL on 18:15 - 17 October, 2019
You can’t really know about suspenders until you get a few miles out of it... but they’re easy to ‘upgrade’ if needed. Loads of them have been used for racing so lots of choice.
Title: Re: Nogs FJ Restoration Project
Post by: Readmarx on 22:51 - 17 October, 2019
What hairy chested chisel jawed man mountain raced FJ’s...? When you ride those old heavyweights its scary to think people did!
Title: Re: Nogs FJ Restoration Project
Post by: CoxyLaad on 21:51 - 21 October, 2019
I've see an few of them on my track day travels. Some ridden pretty hard!
Title: Re: Nogs FJ Restoration Project
Post by: Readmarx on 22:51 - 21 October, 2019
Hats off to the riders with iron test ickles
Title: Re: Nogs FJ Restoration Project
Post by: Rob the Nog on 14:20 - 24 October, 2019
Need to get back on to this really.

Have ordered new brake and clutch lines as the braiding is looking a bit worn in places and the brakes is something I don't want to take half measures with.  Once I fit those I'll start putting it all back together from a mechanical point of view and make sure everythings torqued up properly, and then can begin the look at the plastics.
Title: Re: Nogs FJ Restoration Project
Post by: Readmarx on 19:02 - 24 October, 2019
Yum

Will you test ride it before plastic surgery?
Title: Re: Nogs FJ Restoration Project
Post by: Rob the Nog on 19:48 - 24 October, 2019
Probably not to be honest.

It would need an mot and insurance sorting and then bodge some indicators etc.

It's a risk as I could finish the bike and find it's fundamentally knackered somewhere, but it's looking ok to my eye while stripping it, so I'm hoping it'll be ok to just go for it once finished.
Title: Re: Nogs FJ Restoration Project
Post by: Readmarx on 18:36 - 25 October, 2019
Hairy muff. I've always enjoyed those rides to the MOT... "That's not adjusted right... That's too tight... Pressures wrong... Bit too stiff that.... Did I tighten that..." Adds a nice edge to the ride :0)
Title: Re: Nogs FJ Restoration Project
Post by: Rob the Nog on 19:25 - 25 October, 2019
Lol, yeah I've already forgotten what needs tightening up so I'll just check the lot.
Title: Re: Nogs FJ Restoration Project
Post by: Rob the Nog on 14:52 - 11 November, 2019
Apparently my new clutch line has finally been delivered today (taken nearly a month for them to make!) so can start getting the brakes and clutch reassembled and then start putting bits back together.

The brake likes were a fortune for proper 1TX model brakes as they include the anti-dive parts too, so I just got a company to make me up some Venhill lines the right length to go directly to the calipers which came in at good value.

The existing lines were ok, but the braiding had frayed in a couple of places to the point I wouldn't trust them in an emergency, not worth risking it.

Just getting over a dose of Manthrax but hoping to be back on it soon.
Title: Re: Nogs FJ Restoration Project
Post by: CoxyLaad on 15:49 - 11 November, 2019
I really like the look of these bikes, they seem to make perfect sense for touring to me.

There was a fantastic looking one on facebook for sale last night, r1 forks, thunderace swingarm etc. and they are dirt cheap for what they are.

One day I will build one, the tdm might have to be sacrificed for that to happen however.
Title: Re: Nogs FJ Restoration Project
Post by: BashplateAlAssad on 16:52 - 11 November, 2019
Hm... Thunderace... Yummy.
Title: Re: Nogs FJ Restoration Project
Post by: Rob the Nog on 18:54 - 11 November, 2019
If I was keeping long term I'd probably look into something like that to be honest.
Title: Re: Nogs FJ Restoration Project
Post by: Readmarx on 21:46 - 12 November, 2019
You’ll run the FJ for a bit and then sell it on?
Title: Re: Nogs FJ Restoration Project
Post by: Rob the Nog on 06:17 - 13 November, 2019
Yeah that was the intention.

If I really like it I may keep it a fair while, but thought I'd probably use a bit and then move it on (if I can get a decent price anyway).
Title: Re: Nogs FJ Restoration Project
Post by: Mitch on 19:54 - 13 November, 2019
Reminds me............must look at the Kwaka.
Title: Re: Nogs FJ Restoration Project
Post by: BashplateAlAssad on 12:56 - 14 November, 2019
And me!