[Oldjeep]

No broken...where do you think it is?

Looks welded behind those slotted shelf bracket looking reinforcements that are under the factory rack mounts.
Edit: Now that I see your next pics, the rear of a Gen 1 is a lot different than a Gen 2

 

[WRXer]

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 pulled 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.

 

[WRXer]

Looks welded behind those slotted shelf bracket looking reinforcements that are under the factory rack mounts.
Edit: Now that I see your next pics, the rear of a Gen 1 is a lot different than a Gen 2

View attachment 89978

Looks to be normal Gen I construction, here are two on Ebay....It is different than the Gen II on look.

 

[WRXer]

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.

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).


If the images are small be sure to right click "open image in new tab". Soak it in.

 

[RaYzerman]

Ha, I still woulda power washed it first, lol. Ok, carry on.

 

[WRXer]

Cant. Cold & icey out. That Ariens aint for show.

 

[fjrlee]

Just think of the smile you are going to have on your face when you eventually get it purring like a cat. Great project, lots of parts on EBay, be patient and thorough and you will have a nice bike.

 

[WRXer]

CHAPTER 3--THE TURN

Cleaned the engine, frame & header to the limit of my patience.

 

[Oldjeep]

Looks a lot cleaner than mine. How did you accomplish that?

 

[WRXer]

Mainly a little hand held steamer. No bigger than a coffee pot. The same one I got from Walmart (or similar) to remove the pink elephant borders & flower wallpaper in the house. Several applications since once an area was clean it would get dirty again from the adjacent areas. Often intentionally tipping some extra water out the spout so it was wetter than normal use. Worked really good with minimal mess & water in the garage. Hit the tough spots with a toothbrush then try again. Used a wet scotch brite pad on the header.

 

[StreamRider]

CHAPTER 3--THE TURN

Cleaned the engine, frame & header to the limit of my patience. View attachment 90057 View attachment 90058 View attachment 90059 View attachment 90060 View attachment 90061 View attachment 90063 View attachment 90064

I have seen this before on YT and TikTok....Can't fool me! No way that's the same bike?!?!? Seriously though, if it weren't for the slight rust on the starter anyone on social media would doubt this was the same bike. Amazing job!

Just an opinion: You may want to do more then forum posts of this kind of work as this kind of quality effort makes for amazing content for all sorts of social entertainment mediums. I am sure just this one bike alone could have easily created well over 20 videos and millions of views. Hell you could make a load of free money just taking on the worst of the worst and having your fun with it only to have it pay out solid revenue. Just a thought. Carry on.

 

[fjrlee]

Amazing cleaning job, fantastic - clean or spray the starter body though.

 

[RaYzerman]

What is the mileage on this bike? You might as well do a valve check while you're all wide open, and you would be well advised to change out that "no dot" CCT for sure. I wouldn't trust it after sitting around all this time.

 

[StreamRider]

What is the mileage on this bike? You might as well do a valve check while you're all wide open, and you would be well advised to change out that "no dot" CCT for sure. I wouldn't trust it after sitting around all this time.

What follows is an account of one man's foray into the FJR world. I am posting it here as a retelling of the story I originally penned on another forum so that you FJR enthusiasts may find some amusement--& hope---in these cold dark months known to many of us here in the upper regions of North America.

Much of the thread will be copied & pasted from my original postings as the project progressed in then real time. I will differentiate those posts with italics. Any supplemental or current information & replies will be posted in normal text. Please note this project has already reached its end---whatever end that may be--so any original questions posed in italics need not be answered here...This is an origin story.

I'm pretty sure this bike is all put together and galloping down the highway at this point, Ray.

 

[chazglenn3]

That header turned out awesome!

 

[chazglenn3]

.

 

[natsmada4fjr]

Cripes! That is one dirty and corroded FJR! Never seen one that bad. I don't think it was stored in a barn.

At least the bar end looks to be in good shape:

 

[WRXer]

What is the mileage on this bike? You might as well do a valve check while you're all wide open, and you would be well advised to change out that "no dot" CCT for sure. I wouldn't trust it after sitting around all this time.

At this point in time I was going by the seller's word of "10k-20k" miles. I anticipated getting the CCT question here. I was a complete FJR noob at the time & not involved with this forum, so I knew nothing of FJR CCTs being problematic or updated. I continued happily along in my ignorance. Knowing what I know now, yes, replacing the CCT woudl have been a no brainer at this stage. Hell, wait a couple more posts & you will really be kicking me. Stay tuned.....spoiler alert.....I never changed the CCT. Or checked the valves.

 

[WRXer]

CHAPTER 4--WE CAN REBUILD HIM

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.. As were all the battery / starter / ground cables.

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

How was that for a missed CCT opportunity.

 

[StreamRider]

I kinda wish there was a budget tally going during this whole project to see the overall cost of replacement parts.