New to the forum and man i have a bucket

First off my name is Justin. This is not the first bike i have revived from the dead but probably the worst shape bike i've tried to fix.

https://www.facebook.com/media/set/?set ... 884fa97e6a

This is my current album. I'm in the process of searching for a home so i've kinda put it on the back burner for the moment. Plus i also have a '81 Honda CX500 deluxe and my first bike, a '75 Kawasaki Triple 250, that i'm trying to also bring back from the dead.

The honda runs but has become a money pit. I bought it cheap and wanted to sell it but as soon as i threw it up on craigslist about 9 others showed up and nobody ever came to look at mine...which in my opinion was the most hassle free one. Anyway i still have a bit to go.

I also still need parts so hopefully some of you can help. It is an '85 FJ600, mileage is unknown. I bought it originally to sell th eengine and scrap the bits but i sat on it and realized how comfy it was.

Next thing you know i'm ebaying the hell out of it and buying parts from every bike company i can think of. Enjoy the pictures

 

I would also like the add the reason i'm tearing into the engine. I had the engine off the frame and went to run a compression test at work.

I work at a local ford dealer so i have plenty of tools and of course the shop at work is my garage away from my one car garage at home. Anyway i ran the test and there was absolutely no compression. So at this point i'm down to a frame thats titled and ...well thats about it. Rear wheel from a seca ii or fzr600...i forget which, and a bunch of othere parts that didn't even go to the damn thing.

100 bucks is what i paid for a useable frame and junk engine. anyway, i ran a leakdown test and found 3 of the cylinders leaking out the valves. Cleaned them up and they are ok now but the 4th cylinder (number 3) was leaking out of the rings or through the crank case. I found tons of water intrusion in the cylinder. When i picked up the bike the guy had the engine laying in the yard....nice.

Anyway pulled the piston and it rusted to the cylinder slightly. I actually cheaped out and got some used piston rings for all the cylinders. I mic'd them and they are all to spec but we'll see. I've never used ...used piston rings. I always buy stuff new but i'm on some sort of a budget.

So open it up and find some extremely clean looking cams's and journals. The crank actually had good wear and the plastigauge came out to about .0015 and .002" on all of them with good end play. I can honestly say this thing should fire up fine but who knows about the ignition half.

There's more i can babble on about but its a long long year story. I need to get an engine gasket kit to seal it up at least. I"ll probably be moving in 2 months so i need to keep the dust out. I can't seem to find a gasket kit for an fj but i can find tons of fz600 and radian kits whihc i think i'll do. I know the engine aside from the 12 hp difference should be the same bits and gaskets.

I have also ported out the exhaust a lot. I don't know what the result of which will be. Worked great on my 4 wheelers but i'm not sure why the port had such a large machined hump in the middle of all of them. either for noise or detuning possibly. If it make the bike run awful i'll just slam another head on it and pretend i didn't alter that but again i think i'll be ok with it being the exhaust port.

 

cool, thanks for the update

 

Welcome - I admire your enthusiasm!

You mentioned porting...here's what a great Aussie had to say about such things

http://tuningforspeed.com/files/Tuning_for_Speed.pdf

 

I'll read it in a moment after it downloads but i opened up the exhaust port. I didn't change the diameter of the exhaust port in the top of the head. I gave it a nice mirror finish but the intake i didn't mess with.

I've only ported two things and both of which were 2 stroke 4 wheelers. It was night and day rocket power on the top end but i was a bit afraid to get too crazy with it on the FJ.

I intend on riding it daily and i generally build my stuff right the first time. If i don't know what i'm doing, i usually don't mess with it unless its something that doesn't matter.

Right now i'm messing with the tank i had shipped to me. There's as i said a lot of stuff i still need but i can say that you guys may be interested in another side project of the fj. I bought a D&D exhaust for a suzuki katana 600 for 60 bucks on CL. Well the muffler was rashed and dented in on the bottom section. So i cut 3" off the case of the muffler and cut 1" off the inside baffle. I did this so i could cut the baffle material as well. When all was cut and measured the baffle tube matched up with other end and this was there wasn't a section that was just open to material.

I then just polished out the scratches and drilled new holes to rivet another D&D plate on...which i haven't done. For some reason when you order a D&D plate they ship it ups and it must be signed for to be received.... I keep forgetting to have it shipped to our parts department so i know that i wll get it. Unlikely i'll be home in time and to boot the damn thing is 30 dollars. But ANYWAY, what you gain is a 4-1 exhaust from this. I wanted to use the FZ600's exhaust but heard the frame needed modified to fit. I have a welder and such but i still wasn't sure what difference was and 60 bucks for the full exhaust was a deal to me.

I'm sure my jetting will be crazy as well. I'm planning on running uni-pods since i have no desire to arm wrestle an air box. I've had good luck with uni's in the past and they filter just as much as the stock one in my opinion when the sock filter is used on top of the foam filter. So what i'll have in the end should be the 4 uni's, a slightly ported head, and a 4-1 D&D exhaust with 2" piping to the muffler. I'm hoping for at least 80hp. If the stock is around 70 i don't see what i shouldn't be able to at least squeeze another 10 out of the little tike.

I need to also make some merge collectors for the headers to the exhaust i modded but i haven't figured out how to really get a set up. I know i need about an 11 degree cut but i haven't bought a 14" cutoff machine yet. I've seen a couple of mock set-ups and they seem to work great. I'll post when i do so. Usually when i do a DIY i try to do it with stuff the average person can buy.

Used to always make me irrated when its "Simple DIY to exhaust!" and when you read it mentions "Tools needed: welder....." oh right cause i have 400 dollars laying around to even get started.

 

You got me, i first said oh god, 154 pages...........i've been glued on this for at least 7 pages without a break. Some interesting stuff i can actually understand.

When i was on my triples forum a few years ago they would post 2 stroke theory's or 2 stroke power books and they would usually be a 3-400 page book that used EVERY big word you can think of. Generally including NASA information. This is a pretty good read so far. Thanks man. I have to visit my very very ill grandmother in TN this week so i'll put this on the laptop and read.