FJ1200 Complete engine refresh and rebuilt starter clutch

[@johnross6691]

Excellent job keep building

[@BillCutter310]

Nicely done, Fred. Good job! (bike and video)

[@orpheusness2422]

Be great if you did a series of videos explaining all the work involved

[@halffastfred7602]

I have another FJ engine that consumes oil. I could do a multiple documentary/instruction video series

[@DiamondMounter]

@@halffastfred7602 Im sure that would be greatly received by many FJ owners. I had one a few years ago but sold it before moving to Japan. I really miss it and just bought it back! Organizing shipping at the moment

[@DiamondMounter]

@@halffastfred7602 Also your fork upgrade!

[@bazejprzynoga2169]

Woooow clock is amazing

[@racerrr2231]

Good Work 👍🏾💯💯

[@TheDamnGarage]

Looks good... now it does!

[@Drop.a.gear.disappear]

Amazing work. Where did you get your starter clutch rebuild kit?

[@AndreiGubanov]

very cool! can you told about your custom voltmeter and electronic odometer? is this tuning kit or real foolly handmade once?

[@halffastfred7602]

The gauges are from a company in Orem, Utah, USA. Speed Hut is the company. www.speedhut.com

[@HeirWolfenstein]

Beautiful bike. I’m thinking of picking one up very cheap. It has high miles though. Are they good rebuilders?

[@halffastfred7602]

The rebuild on these engines is pretty straight forward and simple.

[@pneulisse8959]

good job... how many kilometers ?

[@pawemakowiecki823]

Hello, I'm from Poland and I rebuilding my Yamaha. Can you tell me what the tail light is on your motorcycle?

[@IronCK905]

very nice,i want to change the factory handlebar in my fj,can i ask you from which bike is the handlebar base you have so i can fit my new handlebar,sorry for my english

[@halffastfred7602]

The forks and triple clamps are from a 2008 Suzuki GSX-R1000. The handlebars are Woodcraft Technologies

[@rerere523]

What forks have you got on this? I was looking to do the same thing

[@halffastfred7602]

2008 Suzuki GSX-R1000

[@mattdugan9954]

I have a 86 that shifts hard and the clutch is not disengaging fully. Changed the fluid and still didn't help. Any ideas? And cost. Nice job on your bike.

[@halffastfred7602]

I would look at the slave cylinder. Over 30+ years moisture can get past the seals and corrode the cylinder bore.

[@mattdugan9954]

Thanks Fred

[@malcolmgreig5193]

Had a similar problem on my fj1200. Sometimes tiny air bubbles attach to the brake line and the steel tube. With the cap off the master cylinder tap the lines with a screwdriver starting at the bottom. Then slowly squeeze the clutch lever( not to far as to you don't want to push fluid towards the clutch) watch for air bubbles coming out of the tiny hole in the reservoir repeat till no air comes out. Could have warped clutch plates etc. Hope you have it figured out. 👍

[@mattdugan9954]

I honestly got fed up pissing with it and making a mess. So I filled it up again and closed it up. After a couple of days sitting. It decided to start working. 🤷‍♂️ thanks for the help guys. 👍

[@harbertsand]

Big job! How many miles did that one have on it prior to the rebuild?

[@halffastfred7602]

The engine had 62,000 miles on it. The engine did not need to be rebuilt. The starter clutch failed. The lower cases have to be split to do the repair on the starter clutch. I decided that I would put new bearings and rings in since everything was apart.

[@harbertsand]

@@halffastfred7602 Thanks, I’m thinking of buying a 92 FJ1200 with 32,000 miles, preparing myself for the worst.

[@halffastfred7602]

@@harbertsand The lower ends are pretty bulletproof. They upgraded the shift forks starting in 1988. So there is no 2nd gear issues with the 92.

[@harbertsand]

@@halffastfred7602 Thanks for sharing that. Good to know!

[@matthewkeane1257]

@@harbertsand I just bought a 92 with 24,000 miles on it. Be diving in soon to do this!!!!

[@AD-cn2uw]

I need some advice on rebuilding the crank case on my fj1200. Is it best to build everything into the top case and join the bottom section after or vice versa. I'm thinking its best to do it first in the top case because of the starter clutch .

[@halffastfred7602]

I recommend building everything into the lower case. Then place the upper case on.

[@AD-cn2uw]

@@halffastfred7602 Thank you for getting back to me , I questioned which to build everything into first because of trying to position the stater clutch assembly.

[@matthewkeane1257]

What's that contraption at minute 2:20? Some sort of adaptor for a torque wrench?

[@halffastfred7602]

That is a Motion Pro Torque adaptor that allows you to put a regular combination wrench in the adaptor and torque a fastener in a tight space that you can not get a socket in.

[@SP85officiel]

Hi, I just bought a FJ1200 but I have a lot of vibrations. Is it normal ??

[@halffastfred7602]

You should not have much vibrations. I would check the torque on all of the engine mounts.

[@SP85officiel]

@@halffastfred7602 thanks because I have vibrations in my hands and feet, it’s like I have a hair clipper permanently in my hands it’s super unpleasant and it puts tingling in my hands.

[@SP85officiel]

@@halffastfred7602 Should we change the silent blocks of the engine mounts? and if so, do you have references for these parts because the original ones are no longer manufactured.

[@halffastfred7602]

What year is your FJ?

[@SP85officiel]

@@halffastfred7602 December 1991

[@seijitanaka2275]

Which meter did you transplant?

[@halffastfred7602]

If you mean the gauges. They are from www.speedhut.com

[@МишаСилюков]

hello, please help me with advice on the starter chain

[@halffastfred7602]

I can try....

[@МишаСилюков]

is there a generator chain tensioner on the 1200 ? or just a sedative ?

[@halffastfred7602]

There is a starter clutch chain guide that does provide a bit of tension. At start up and low rpms, you may hear a rattle from the engine. This is very common and not something that you need to worry about. The chain does get loose and the rattle that you hear is the chain rubbing on the starter clutch oil nozzle.

[@МишаСилюков]

@@halffastfred7602 I have a strong rumble , I took off the engine, took off the pallet and realized that my usplklitel broke (garbage in the internal combustion engine)

[@МишаСилюков]

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