New Project...FJR1300 - Wrist Twisters
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post #1 of 57 Old 11-18-2019, 07:34 PM Thread Starter
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New Project...FJR1300

Took in a FJR1300 project...2004. Bike has not ran in 6+ years & stinks of bad gas at 10 paces. Mice ate the seats. Has been sitting in a barn for 6 years then outside for the last 5 months. As rescued...
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post #2 of 57 Old 11-18-2019, 07:50 PM Thread Starter
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Just been able to briefly look over the bike. Hole in the top of the gas tank....maybe just a a vent chamber as the tank is full (of something) & it does not splash out. Also removed the seat & the mouse damage is worse than I hoped, but not as bad I have seen before. Other than the seat they started eating the plastic inner fender/under tray, 1/2" hole thru the top of the air box, a little of the rear cowl, & the insulation of a wire or two (so far). Of course all the gross & corrosive action of the mouse pee too. Not brave enough to get inside the airbox yet. A lot of the main harness/ECU wiring is down by the air intake also so will have to see what kind of damage was done around there. On my last project (YZ125) mouse pee completely ruined the bike..nest in the airbox & the mouse pee ran down...melted the carburetor ....then continued on & ruined the crank & cases. There was no saving that one. This one is not near that level (that I have seen yet) & at least the airbox is below the intakes so that cant happen here.

Rolls a lot easier with air in the tires. Looking for a set of seats & a windscreen that isn't blue (stock height preferred) if anyone has one laying around the garage cheap.

Never dealt with old/gummed up gas in a FI bike before. What do you do? Just replace the fuel injectors instead of trying to use or clean them?
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post #3 of 57 Old 11-18-2019, 11:13 PM
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I hope the price was right on this one...

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post #4 of 57 Old 11-19-2019, 02:33 AM
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Looks awesome so far. I was going to suggest a seat cover from eBay and cut some foam or have it reworked by a pro.

I did a tow yard restore on a Nighthawk 700S back about 15 years ago. It was missing quite a few parts. I got it for free and was able to unfreeze the rings and get it running. Bought a parts bike for $400 and had pretty much all the parts I needed to get it running.

Few tips: I'm sure you understand motorcycle tires and how they age, after about 5 years, they're not good any more. The tricky parts are the seals and brakes. I had stuff in the brake system that locked up the brakes. The plastic site viewer started melting into the fluid and made it so that the brakes wouldn't return.

Cables, seals, fluids, etc... Sadly a bike sitting really doesn't do it any favors and outside in the weather can really damage the rubber seals. Things like the brake seals inside, you can't see them until you pull it all apart, but they can go at any time.

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post #5 of 57 Old 11-23-2019, 08:31 AM
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People have had good luck soaking their carbs in Pine Sol

https://advrider.com/f/threads/the-p...thread.560117/

But for $150 there's no reason not to buy a new set

https://www.ebay.com/itm/2004-yamaha...cAAOSwgPNdcSFu
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2007 919
2003 CBR1100XX
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post #6 of 57 Old 11-26-2019, 07:15 PM Thread Starter
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Ventured further in...
Opened the gas cap & found heavy corrosion around the filler neck, liquid pretty much full. Siphoned out all the liquid to the tune of around 4 gallons (in a 6+ gallon tank). Could tell the tank has alot of sediment or solids in it so I assume the fuel pump is not going to make it but I have not pulled it or even looked in with a flashlight yet. Yanked the tank from the bike then went after the air box. No mice live or dead but they sawed though the main wiring harness near the ECU. So far the shopping list includes fuel tank, inner/rear fender, air box, wiring harnesses (this bike has several--need main & injector harnesses at minimum) & probably fuel pump & complete fuel rail. I assume I could reuse the throttle bodies themselves but may replace everything else for peace of mid if nothing else. The good news is the smell in the garage is improving & in general parts are plentiful & reasonable for FJRs. The exception being Gen I (03-05) fuel pumps...currently not much out there & used ones cost more than a new one from Yamaha.

Note the hole in the air box & no wires leading to the intake temp sensor.
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post #7 of 57 Old 11-28-2019, 07:12 AM
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I have a stock windscreen in a box from my 2006 FJR.

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post #8 of 57 Old 11-29-2019, 06:30 AM Thread Starter
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Thanks for the heads up but from my research I need something from an 03-05 correct?

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post #9 of 57 Old 12-01-2019, 05:17 PM Thread Starter
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Continuing to peel back the onion. Eventually, beneath the layers of plastic, wiring, & hoses you can start to make out parts that resemble an actual motorcycle. Removing the main front fairing around the dash & headlight was a challenge when you don't know where the fasteners & all the little interlocking tabs are. The FSM wasn't much help either. Finally got it without breaking anything.

I pul;led the fuel pump & don't see how it could be saved with the corrosion in the tank. Despite the funk in the tank, the rest of the fuel system downstream may actually be salvageable.

I was also able to determine the FJR has Throttlemeister bar ends with cruise control.
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post #10 of 57 Old 12-01-2019, 07:13 PM
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You're a very brave fellow.

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post #11 of 57 Old 12-01-2019, 07:59 PM
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Quote:
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You're a very brave fellow.
Yeah...I was thinking the same thing.
But you never know.
That bike sure got grimy underneath.
Good luck mate.

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post #12 of 57 Old 12-02-2019, 08:35 AM
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You have a Labor of Love project on your hands now.
Best of fortune to you.

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Never said I didn't know how to use it."
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post #13 of 57 Old 12-02-2019, 07:45 PM Thread Starter
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Almost to the turn. Bad spinal cord removed. Got to look in the intake ports....looks like the day it was made. No dirt or foreign matter. Not even a hint of carbon or buildup. Looks like brand new x4. Since it has no electrical system I was never able to check miles at the odometer. I have been operating under the seller's word that it had "ten to twenty" thousand miles on it. Guy I bought it from was the original owner who bought it new.
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post #14 of 57 Old 12-03-2019, 01:03 AM
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Once you get all that grime off it'll look much better.

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post #15 of 57 Old 12-08-2019, 07:31 PM Thread Starter
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One last pic of the before....Finally have it broken down to the point I can start going the other way. The amount of space a fully disassembled FJR takes up is staggering. I have parts stuffed everywhere. The mice really did a number on this wiring, but it will be fixed right (replaced).
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post #16 of 57 Old 12-09-2019, 12:44 AM
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That pic is triggering my cleaning OCD!

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post #17 of 57 Old 12-14-2019, 01:25 PM Thread Starter
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Could use you because I can't stand it.
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post #18 of 57 Old 12-15-2019, 07:59 AM Thread Starter
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Cleaned the engine, frame & header to the limit of my patience.




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post #19 of 57 Old 12-15-2019, 09:50 AM
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There you go! Islandboy will be able to relax a bit now...

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post #20 of 57 Old 12-15-2019, 03:20 PM
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Ahhh!..much better. Although that starter motor is giving me pause.

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post #21 of 57 Old 12-16-2019, 04:44 PM Thread Starter
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The mice did not stop at the main harnesses. Every wire must be inspected. I could patch, solder, or put new ends on some of the lesser damaged wires but I do not want to go back into this bike again, chase electrical gremlins, or be left stranded (it is a touring bike after all) so any wire that is compromised is being replaced.

The stator output, cam position sensor, & O2 sensor wires were untouched. The jumper from the neutral switch to the main harness was fine but I am replacing it with the one that came with the replacement main harness anyway.

Did a cold oil & filter change..


The bullet end of the oil level sensor melted off so the entire sensor was replaced. No end circled...


Replacement...


The output speed sensor wires were nibbled on so it was replaced. This is between the engine & shock/swingarm. The connector does not fit between the engine & frame so I had to release the pins from the connector otherwise I could not get the replacement in.



Starter cable insulation chewed thru so it was replaced..


& Finally the crank position sensor was replaced due to compromised wires.


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post #22 of 57 Old 12-16-2019, 07:16 PM Thread Starter
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Replacement harnesses. Headlight harness, main harness, injector harness, & tail light harness complete with bonus tail light. The ignition switch, side stand switch, & handlebar controls were spared.

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post #23 of 57 Old 12-17-2019, 07:17 PM
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Ya know, Bryce, if you replace the tank, and everything that is rubber and or plastic, you might have something there. But man, that's a lot of work. I gotta hand it to you for undertaking such an endeavor.

It drives me crazy when people neglect/destroy what was once a really nice motorcycle. If the PO has hosed that thing down with a couple of cans of Honda polish, tossed a sheet over it, dumped a bunch of Sta-Bil in the tank. and bought a bucket of rat poison when he parked it, it would have taken less than 2 hours to get it cleaned up, and running.

I'm a firm believer that motorcycles belong in the house.

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post #24 of 57 Old 12-21-2019, 06:39 PM Thread Starter
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Replaced the spark plugs since I had once in a lifetime access...once they were out had the same impression as when I did the 919...is this really necessary?

They look black in the pics but in person they look good, should be running just fine.

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post #25 of 57 Old 12-24-2019, 06:18 AM Thread Starter
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Installed the new main harness & have begun layering all the wires & hoses back in with many more yet to go. The dozens of photos I took during disassembly are invaluable.



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post #26 of 57 Old 01-01-2020, 07:17 PM Thread Starter
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Got the cooling system & all the wires that reside under the left & right main fairings reinstalled & sorted. Can't fill the cooling system yet since there is a loop that runs thru the throttle bodies. Those left & right wiring bunches & hoses snaked around each other & the surrounding frame to radiator cowling will test you. The headlight harness & handlebar controls feed in thru the steering head & tie in to the remaining connectors under the tank then the AIS hoses plop on top last. Had enough wiring & cable routing for now--moving on to suspension for a change of pace.




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post #27 of 57 Old 01-02-2020, 10:05 AM
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Beautiful! What a difference a good cleaning makes.

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post #28 of 57 Old 01-13-2020, 08:07 PM Thread Starter
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Haz replacement seats (stock). I must be an optimist.


Rear suspension on after buying gigantic allen/hex drive (19mm) & regular (36mm) sockets.



Front suspension getting new oil--that old stuff stunk
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post #29 of 57 Old 02-04-2020, 08:24 PM Thread Starter
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After letting the fork drain for a few weeks (not intentional) I filled each leg with a few ounces of fresh fluid, cycled them for a few minutes, drained them again, then filled them up for good. One upper tube had a single rust pit spec on it in the travel portion, so I dressed it down with emery cloth.



Swapping out the mouse eaten rear fender & air box for fresh ones.





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post #30 of 57 Old 02-05-2020, 02:58 PM
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Nice work and lookin' good!

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post #31 of 57 Old 02-05-2020, 04:27 PM
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Filthy rodents.

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post #32 of 57 Old 02-08-2020, 05:37 PM Thread Starter
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**NEED HELP**

The gauge buttons are supposed to look like this:


The mice chewed mine so they look like this:


In addition to no longer being weather tight the rubber caps now no longer activate the switches below that look like this (& seem to function fine):


I REALLY do not want to buy a used cluster for around $60 just to pry out the rubber buttons. Anyone know a source to get replacement buttons?
One in one out



Back


Front

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post #33 of 57 Old 02-12-2020, 05:45 PM Thread Starter
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Dismounted the rotors & scrubbed them with water & a Scotch-Brite. Same with the pads (all interstate use, barley used). Cleaned the calipers, pad springs, & wheels with wheel cleaner. Tires only after I hear it run.



Bled front brake & clutch.




Letting the rear diff drain for a few days.


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post #34 of 57 Old 02-12-2020, 08:34 PM
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Mate, when you finish with this, you should take on something more modest, like a plan for peace in the Middle East, or resolving the climate crisis - something a bit more straightforward.
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post #35 of 57 Old 02-13-2020, 08:35 PM Thread Starter
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Quote:
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Mate, when you finish with this, you should take on something more modest, like a plan for peace in the Middle East, or resolving the climate crisis - something a bit more straightforward.
Got a chuckle out of that one. I usually get a winter project every year, but I'm definitely earning some new merit badges on this one.

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post #36 of 57 Old 02-15-2020, 02:52 PM
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Well, that impressed the living shit out of me!

“I said I never had much use for one.
Never said I didn't know how to use it."
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post #37 of 57 Old 02-15-2020, 03:15 PM
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Well, that impressed the living shit out of me!
Same.
There are several very handy lads kicking about on this site.

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post #38 of 57 Old 02-18-2020, 08:11 PM Thread Starter
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U-joint cleaned up nice with just WD-40 & a rag. Feels nice & smooth. The gurus on the FJR boards swear by this special Honda lube for the splines on both sides of the U-joint. The current exchange rate is 1 tiny tube = $20. At least I get to use it on the rear diff to rear wheel connection too.


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post #39 of 57 Old 02-18-2020, 08:44 PM
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Bike is looking super crisp, can't wait to see it fully re-assembled !

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post #40 of 57 Old 02-22-2020, 09:06 PM Thread Starter
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I put an end to my speedo button saga. Went ahead & got the replacement cluster for $60 & plucked out the damn buttons.


Note NONE of this disassembly of the gauge unit was really necessary to replace the buttons. They could just be popped in & out thru the front. Of course I only know this in hindsight, did not know if there was a little peg or rod in between the button & gauge & did not want it to fall out or disappear without me seeing where it went first; or know how the buttons on the circuit board worked. As it turns out they are built right into the buttons. Here they are....$60 worth. Mice.


So I did the usual clean everything & put it back together. Ready to go.


At least I can move on now. Like getting to clean this.... EVERY piece on this motorcycle is this dirty or worse.

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