... very early in the morning... way up ahead was another motorcycle so I rolled on the throttle to take a look when, as i was entering the triple digits, power began to taper off... hmm, plenty of fuel, oil pressure okay.... lost a cylinder for some reason... limped 60 miles home and discovered #2 cylinder low on compression (as in no compression!) Valve clearance was in spec.... looks as if a valve burned...!
Following a phone call to Randy and Robert, a few days later, loading up the FJ into a trailer I ventured to the RPM shop. Despite a busy schedule, they quickly had the engine out & head off and sure enough, one valve gone with another just beginning to leak. As i was beginning to use oil, no doubt an overhaul was soon to be in the cards anyway.
RPM is keeping me informed of the progress; tear down is complete and reassembly is scheduled late next week - which indicates a fairly quick turn around despite the fact it was an unplanned event. Because of the high mileage, it was decided to install new pistons, rings, bearings cam chains et al- as all the parts are in stock there is no waiting on parts - just waiting for time in their busy schedule to complete assembly.
So, no ECFR in Tennessee this month, but in a few weeks following break in and a few shake down runs, the old FJ will be ready to roll one again... and not so old after all...!
Thanks RPM.
Midget.
Quote from: Mike Ramos on September 02, 2016, 05:56:14 PM
So, no ECFR in Tennessee this month, but in a few weeks following break in and a few shake down runs, the old FJ will be ready to roll one again... and not so old after all...!
Thanks RPM.
Midget.
Dammit, Mike... at least the damage (considering all) was minimal.
You'll be missed in BCNC, for sure.
See you next season... ;)
Hi, Mike
High mileage?, how many miles?. Mine is now showing 152.000 miles at the Odo without engine problems. Maybe is it due to the gas quality there?
Regards
Alf
If your valve clearances were in spec Mike why would your valves burn out.?
Quote from: Bones on September 03, 2016, 04:02:18 AM
If your valve clearances were in spec Mike why would your valves burn out.?
There can be several reasons for this. The valves were run out adjustment and started to burn, before Mike got the bike. It could also be a bad valve or something got stuck between the valve and seat, which started the process of burning the valve, then broke free. In my opinion this was a problem Mike inherited.
Sorry to read of your misfortune. I'm glad you were close to home when this happened. Wishing you, many happy ridding miles.
Kurt
Quote from: Alf on September 03, 2016, 03:42:07 AM
Hi, Mike
High mileage?, how many miles?. Mine is now showing 152.000 miles at the Odo without engine problems. Maybe is it due to the gas quality there?
Regards
Alf
LOL, I think Mike passed 152 a long time ago....
I shudder to think of how many are to come with a fresh rebuild...
I am not sure sure it burned the valve as it looks like it just flaked off.
(http://i1215.photobucket.com/albums/cc517/racerrad8/IMG_2586_zpsxnkl7vdg.jpg~original) (http://s1215.photobucket.com/user/racerrad8/media/IMG_2586_zpsxnkl7vdg.jpg.html)
Head & cylinders off to the machine shop last week.
Rest of the engine has been torn down and given the first cleaning to get the massive amounts of road gunk off of it.
(http://i1215.photobucket.com/albums/cc517/racerrad8/IMG_2608_zpsygummdis.jpg~original) (http://s1215.photobucket.com/user/racerrad8/media/IMG_2608_zpsygummdis.jpg.html)
It was very obvious why the starter chain was so noisy...
(http://i1215.photobucket.com/albums/cc517/racerrad8/IMG_2606_zpsgkaycdv3.jpg~original) (http://s1215.photobucket.com/user/racerrad8/media/IMG_2606_zpsgkaycdv3.jpg.html)
(http://i1215.photobucket.com/albums/cc517/racerrad8/IMG_2607_zpsrkwuthpm.jpg~original) (http://s1215.photobucket.com/user/racerrad8/media/IMG_2607_zpsrkwuthpm.jpg.html)
Randy - RPM
Those spark plugs are Super clean, how long have they been in for? Mine look worse than that after a short 2 hour ride!
I hope that's not the reason why I hear a noise ever now and then.
Alan
Quote from: Sparky84 on September 05, 2016, 07:31:13 PM
Those spark plugs are Super clean, how long have they been in for? Mine look worse than that after a short 2 hour ride!
I hope that's not the reason why I hear a noise ever now and then.
Alan
Those were installed in July. He was having a little misfire. The plugs were so caked with oil ash it was decided to replace them. The looked like the center of the intake valve across from the bad exhaust valve.
He has been using a ton of oil as well. So, I would say 3-5K miles since they were replaced.
Just look at the oil smoke from the muffler back int he spring of 2105. That is also synthetic oil so the smoke is much less than conventional oil. Mike is in front of Rick for the majority of the video.
https://youtu.be/ZBiDNhqd4ck
Randy - RPM
Quote from: Alf on September 03, 2016, 03:42:07 AM
Hi, Mike
High mileage?, how many miles?. Mine is now showing 152.000 miles at the Odo without engine problems. Maybe is it due to the gas quality there?
Regards
Alf
Hello Alf,
The 1991 had 174,000 (sometimes hard) miles as of 3 years ago (it was purchased it at 27,000 miles) - it was then sold to a fellow who uses it mainly as a commuter to work. As far as i know it is still running.
This 1992 engine has... er had... 108,000 miles and although it was in excellent condition cosmetically when purchased, it sat for extended periods of time as the previous owner was often at sea. But it was purchased at 22,200 miles so I cannot really complain - it never let me down and still performed well.
I do not abuse the equipment however I do use it hard at times...
Ride safe,
Mike
Quote from: yamaha fj rider on September 03, 2016, 02:07:59 PM
Quote from: Bones on September 03, 2016, 04:02:18 AM
If your valve clearances were in spec Mike why would your valves burn out.?
There can be several reasons for this. The valves were run out adjustment and started to burn, before Mike got the bike. It could also be a bad valve or something got stuck between the valve and seat, which started the process of burning the valve, then broke free. In my opinion this was a problem Mike inherited.
Sorry to read of your misfortune. I'm glad you were close to home when this happened. Wishing you, many happy ridding miles.
Kurt
Hello Kurt!
Yep, part of it was inherited however I do not believe it was intentional. The bike had set for extended intervals prior to purchase and after 24 years of service (heck, that's even older than me!) something had to give. But all in all I cannot complain.
See you at a Rally before too long!
(and I never mentioned the noise-maker at the last WCR...!)
Mike.
Thanks, Mike . It was only curiosity
Best regards and ride safe much more miles
Alf
Quote from: ZOA NOM on September 04, 2016, 05:37:53 AM
Quote from: Alf on September 03, 2016, 03:42:07 AM
Hi, Mike
High mileage?, how many miles?. Mine is now showing 152.000 miles at the Odo without engine problems. Maybe is it due to the gas quality there?
Regards
Alf
LOL, I think Mike passed 152 a long time ago....
I shudder to think of how many are to come with a fresh rebuild...
Greetings Rick!
Yep, I will have just gotten into high gear - so to speak - (and plan on a whole lot of miles) with the new engine!!!
It is my belief that, after weighing the various options available, a complete rebuild provides the best "cost vs. value" and is actually less than presumed; especially when, based on previous experience, high mileage from a properly rebuilt engine can be expected. And considering the rest of the bike has all the modifications and updates available, it will be a sound investment.
When I sold the 1991 with high mileage, it was running well and was a sound motorcycle. I did look at a nice 1992 in san Diego with 35,000 miles a few months ago HOWEVER, I could not in good conscience sell this 1992 to anyone knowing it was on its' last legs.
Plus, I would be purchasing an unknown quantity and although another FJ would seem to cost some what less than an engine overhaul, considering the miles I ride (and the isolated areas I roam) I would be repeating this all over again within just a few years.
So, rather than start at 35,000 (or so) and take my chances (and perhaps once again inheriting another problem), when the true and actual "cost per mile' is figured when starting a ZERO miles - and knowing the rest of the chassis is also "as new" then I am practically, in fact actually I am getting a new motorcycle...!
As an aside, the engine will remain stock with just the over size pistons being the only change (I think it makes it a 1202cc - 1188cc original..?)
Let the fun begin...
Ride safe,
Mike Ramos
Well, the progress continues. I like, if possible, to be able to allow the bike owner to participate.
Mike did 95% of the tear down of the engine. It made him really nervous as things were being disassembled they were not being laid out in order...everything just goes into a basket for cleaning.
I told him the next time he came down, I would have him clean up his bike since it has hundreds of thousands of miles on it. It is a perfect opportunity to clean while the engine is out. You get to see places that are never visible with the engine in the bike.
So, I gave him some cleaner, an apron and a pressure washer. I told him to wash it, then we will look at it and wash it again...
He gave it the initial wash and was surprised how many spots he missed. So, the second washing Robert took over after I gave Mike a soapy rag to wash the wheels. I can here Robert saying...you missed a spot under here.
At the end of the day the bike is probably cleaner than the day he bought it.
The head is back from the machine shop, waiting on the cylinders then it is time to put the puzzle back together.
Randy - RPM
This is the funniest post I've read in some time. Glad to see Mike's bike is getting the expert attention it deserves. I think Mike like me, is more concerned with maintenance and riding than how clean his bike is. If he wasn't he would be riding a Harley.
Don't worry about dumping all the parts in a pile Mike--I think Randy knows where they go and in what order. :biggrin:
Ride safer than me
Dave
Mike looks like he's having a blast riding the learning curve.
Knowledge is a wonderful thing and the Fj community being littered with experts means an owner is never left high and dry.
Best of British with your spannering; a rally approachth.
Fj gods speed your progress
Quote from: racerrad8 on September 23, 2016, 10:21:15 AM
Well, the progress continues. I like, if possible, to be able to allow the bike owner to participate.
Mike did 95% of the tear down of the engine. It made him really nervous as things were being disassembled they were not being laid out in order...everything just goes into a basket for cleaning.
I told him the next time he came down, I would have him clean up his bike since it has hundreds of thousands of miles on it. It is a perfect opportunity to clean while the engine is out. You get to see places that are never visible with the engine in the bike.
So, I gave him some cleaner, an apron and a pressure washer. I told him to wash it, then we will look at it and wash it again...
He gave it the initial wash and was surprised how many spots he missed. So, the second washing Robert took over after I gave Mike a soapy rag to wash the wheels. I can here Robert saying...you missed a spot under here.
At the end of the day the bike is probably cleaner than the day he bought it.
The head is back from the machine shop, waiting on the cylinders then it is time to put the puzzle back together.
Randy - RPM
Gentlemen, yes I got nervous! I usually set bolts and parts out as i disassemble, especially when i am not too familiar with the internals of an engine. However after several mishaps (e.g. I did not realize the airgun was in tighten mode and broke off a couple of case bolts (thank goodness for those EZ-OUT tools!) dropping the cams on the ground and braking a few fins off of the head - I may have stripped a spark plug as well; never use an air tool on the spark plugs!
Robert finally said "Dude, you're killing me!" and took over, thus ended my tear down chapter... Yep, out behind the palatial RPM shop on their special steam cleaning pad I tried to use the heated steam cleaner pressure washer but alas, you can see Robert finishing what I missed after several honest to goodness tries... Finally Randy said, "Little man, stay away from the mechanics" and had me take pictures....
It can now be argued conclusively that looks are deceiving - look at the picture of Randy overseeing Robert using the pressure washer; would anyone trust their engine to a fellow who wears a goofy looking hat? Not to mention Mr. R really should shave that goatee if he wants credibility... And look at those silly shades not to mention such poor posture....
Oh and Texas Dave, nothing funny about anything - this is serious stuff!
Looks as if the Renegade Rally is shaping up nicely...!
Ride safe & see you there.
Oh Mike, It will be alright . The guys will get you all fixed up in no time and your bike will roar to life once again. :drinks:
Hey Mike, FYI, I'm bring up to the RR a Rifle windscreen for you to try....
http://rifle.com/Motorcycle-Windshields/Yamaha/Yamaha-FJ1200-Windshield-System1991-1993.aspx (http://rifle.com/Motorcycle-Windshields/Yamaha/Yamaha-FJ1200-Windshield-System1991-1993.aspx)
It has the small 13" clear top screen. It should work pretty good...
Well, I made a choice not to get the NYT TRN2 done before the renegade rally. It would have been a fresh build and there would have not been any break-in time on the engine. But progress has again begun to get it back into service.
I have never taken either of the engine chains and did a comparison of new to old. These old chains out of the engine have more than 100,000 mile on them. While the stretch doesn't seem to be too bad, the starter chain is the source of the idle engine noise on older engines.
The started chain has no form of tensioning on the chain so it just flops around as the chain wears. I was also surprised how far the old starter chain can bend backwards compared to the new one.
The timing chain has the tensioner to keep it taught but with chain stretch the camshaft become more & more retarded from TDC.
More to come as the build begins to get into gear later this week.
The first three are the timing chain and the rest are the starter chain.
Randy - RPM
Time for an update...
I was able to stop by the palatial RPM shop early this week - despite their very busy schedule, work on the '92 FJ is progressing nicely.
The engine assembly is complete (!) and upon my arrival it was just being moved into the state of the art painting booth - I am not sure of the brand of paint, but the spray gun was top of the line (not a H.F. special) and the finish was impressive. As it was explained to me, the paint will be allowed to cure under heat lamps for a specific amount of time, thus ensuring a curing process that, should any finger prints or smudges appear, they can easily be wiped off. Another plus is that in the future bugs and road grime will easily wash off.
While I requested a red crank case, white barrels & a blue head assembly to show my patriotism (granted after a look of disbelief by the whole RPM crew), apparently as it was explained to me, I could have any color as long as it was black - I suppose it affords some kind of tradition. Anyways, with the polished cooling fin edges, it will look just fine.
There were two cars that were being serviced - one with overhead cams and fuel injection, as in EFI... hmmm, I did not know that Legend cars had EFI systems...
So, I should be riding my own FJ by next week... assuming the car with the EFI does not run into unexpected assembly problems...
Just an observation!
Ah yes... nothing like progress :yahoo:
Okay, engine assembly is complete & engine installed; fairing polished and the aluminum too!
Enjoyed picture perfect weather at the RPM shop and mostly I enjoyed a one hour trouble free shake down ride accompanied by Robert leading me through the quiet country back roads.
Everything checked out perfect: engine was as smooth as ever and the transmission never shifted so well...!
I have a car ride lined up tomorrow back to RPM to drop me off & I plan on an easy break in ride down to San Diego.
Much thanks to Randy and Robert for the excellent service and a job well done!
Pictures tomorrow showing the various stages of installation.
Until then - & of course ride safe...!
Nothing like having your own bike back. Not that you were any slouch on those borrowed wheels at the Renegade. Select those gears positively.
Sweet news Mike! Let's make some more video without the smoke this time!
Quote from: Mike Ramos on November 03, 2016, 12:20:34 AM
Ah yes... nothing like progress :yahoo:
Okay, engine assembly is complete & engine installed...... and mostly I enjoyed a one hour trouble free shake down ride ........
Excellent stuff Mike, good to see you back on the road and the bike purring.
Noel
Good evening Gentleman,
So it has been 6,130 miles since the engine overhaul and past due for an update.....
A BRIEF REVIEW: the engine lost a valve at just under 108K miles. The conversation then focused on whether to look for another used FJ or have this one rebuilt. Weighing the pros & cons, especially considering the many modifications which have been incorporated (also I had recently replaced all the suspension linkage, swing arm, steering head and wheel bearings) it was not difficult to take the decision favoring an engine rebuild.
I was able to stop by the RPM shop occasionally during the rebuild and Randy's experience is in evidence to the smallest detail.
VERDICT: It is an understatement to say the new engine is running flawlessly! :yahoo:
Cold starts are almost instantaneous. There is noticeably more power available than before and the engine, while always smooth, has even less vibration than previously. There are absolutely no oil leaks or seepage. Oil consumption, if any, is negligible. :good2:
Added bonus: Robert is quite the instructor & his attention to detail is admirable. Noticing that several fairing tabs were cracked on at least one of the fairing mounting points, they were repaired better than new. I was shown how to quickly remove the fairing. A simple procedure; one which takes almost less time to do than reading about it.
Several rides of note: First, apologies to those back east and other environs where riding is seasonal.... While we have had a lot of rain, there has been a limited amount of icy cold, riding limiting weather.
A spectacular late night run from San Diego to far northern California on Hwy 101 – almost no traffic north of Los Angles, passed through the Bay Area in the early morning hours and further north crossed over to the eastern part of the state. All in all a very satisfying sojourn.
Another ride from far northern California last Friday evening.
And finally another 400 plus miles Sunday (leaving in the early morning, spending the day visiting) and returning late night.
Ah yes, nothing like a well running FJ....
Again, much appreciation to Randy and the R.P.M. staff.
Ride safe,
Mike Ramos.
most excellent Mike,
Although the weather has been wet here and there , we have had many great days to sneak in a good ride .
glad the new rebuild is working out. :good2: