got one. looks like my hoses from oil cooler. at bracket that bolts to the engine. common? gunna replace em. have cleaned and filled up with oil again, took 1 litre, further diagnostics coming .( meaning i ll go fro a ride and 'ave a butchers) just to save me does anyone know if can be converted to replace hoses only? looks like a moulded one piece pipe, no JIC fittings or the such.... contemplating cutting hard pipe and flaring to make a jic fiitting but looks again like a pain in the ar*se at the oil cooler end.... input preciated.... not critical just needs to be fixed. :good2: :ireful:
Neil......talk to Randy....JIC fittings are on the Legends engines........I did mine when I installed the bigger cooler and got new hoses made.
Harvy
sounds like its time for a oil cooler upgrade.
KOokaloo!
Or replace it with a stock unit another owner may have for sale or better yet someone who has upgraded to a better part and no longer needs the stock cooler. I bet theres one around here...
Eric M
Quote from: Yamifj1200 on October 31, 2010, 10:05:22 PM
Or replace it with a stock unit another owner may have for sale or better yet someone who has upgraded to a better part and no longer needs the stock cooler. I bet theres one around here...
Eric M
Good thought Eric....... Neil, I've got a couple of stockers here.........a '90 or a '91.
Take your pick.......I owe you anyway!
Harvy
Thats the good thing about this group. Folks willing to help others out... Your a good bloke Harvy!!!!!
Eric M
Dammit...there is nothing wrong with upgrading!
you do what you want to Kopfjaeger :good2:
Kookaloo! (fer upgrades) :biggrin:
Quote from: Yamifj1200 on October 31, 2010, 10:55:00 PM
Your a good bloke Harvy!!!!!
Eric M
+1 :good2:
Randy T
Indy
Quote from: Kopfjaeger on October 31, 2010, 07:02:22 PM
got one. looks like my hoses from oil cooler. at bracket that bolts to the engine. common? gunna replace em. have cleaned and filled up with oil again, took 1 litre, further diagnostics coming .( meaning i ll go fro a ride and 'ave a butchers) just to save me does anyone know if can be converted to replace hoses only? looks like a moulded one piece pipe, no JIC fittings or the such.... contemplating cutting hard pipe and flaring to make a jic fiitting but looks again like a pain in the ar*se at the oil cooler end.... input preciated.... not critical just needs to be fixed. :good2: :ireful:
Kopfjaeger,
I had this problem with the older of my two FJs. After a winter lay off it was spewing oil from the oil cooler metal pipe. The pipe had corroded through behind the clip onto the engine. At the time the bike had done 113,000 miles and run through a lot of crappy British weather – so it's not likely to be a common problem. A visit to my local Yamaha dealer provided a nasty shock – the pipes were £90 (145 USD) each! - and that was 5 years ago. I then looked for a cheap repair. I obtained a length of rubber oil pipe, cut out the metal pipe and replaced it. This has worked fine for 5 years/20,000 miles. If I had the same problem again I'd get a cooler with pipes off eBay. They are common and cheap here in the UK.
(http://farm2.static.flickr.com/1331/5133513447_28d7f316ed_z.jpg)
The pipes look ok, but....
(http://farm5.static.flickr.com/4148/5134099896_8274cb6abb_z.jpg)
Rust hole behind clip.
(http://farm5.static.flickr.com/4129/5134100816_a9aa3fd1e6_z.jpg)
Rubber oil pipe.
(http://farm2.static.flickr.com/1403/5134100136_966a0d3a68_z.jpg)
Repaired pipes - not pretty, but ok for a "work-horse" bike
Stuart (Glasgow, Scotland)
cheers fellas. and thanks harvey im looking into it havnt had much of a chance (bloody work!!) i like your upgrade stuart was thinking along the same lines as yourself and "borrowing" some FRAS covered pre made hoses from work :good2: but i dont think its going to be an option. looked into braided lines yesterday at the bike shop... bit pricey so thats on hold. i might grab those coolers and hoses of you harvey let me know how much and we will tee it up. always good to have spares!!! will a 91 fit on an 86? dont think it would be any different.
cheers again.
on the plus side at least my oil light in the dash works!!! :good2:
:good2: looking good so far. cant get the oil pipes off without taking the headers off so after a wrestle me vs bolt that holds the collector to the frame i finally got it and then the lines off, have degreased engine, greased front wheel and bearings and have all that back together, leaving over night to let oil do its thing, new filters o rings for the oil filter, and a thourough thourough clean and polish. been dirty for too long did you know the dog bones and rear linkage were silver? i didnt!!! :shok:. thank you to harvey those lines were a treat, :music: :dance2:bit of a flush and change of o rings and straight in!! thanks for the spare bolts too mine were cr*p!! if its not the lines i cant work it out. the barrell section on the front finning is oily. the gaskets are dry no weeping it starts at the fin below the gasket. no rocker cover leaks new plugs no evidence of oil squirting out there, i know stuff can wick but up that far? its a bit wild sorry i dont have pics. most dreaded thought is a busted oil gallery that will weep out under pressure?? as i have said i have cleaned it and will hit it again tomorrow... need sleep .. been for a ride up to wootton with a mate on his cbr 600 f and then got home and started work . wouldnt be ded fer quids eh? :boredom:
ok got the source of the leak. at the front of the engine, where the cam chain runs behind that bulge in the casing, under the 2 nuts there is about 3 fins, its the middle one of those, i cleaned the engine and i can see it slow drip, i cant see where its running from it looks like the base of that paticular fin :shok: :cray: took buckets of oil as was too be expected , cos i drained and flushed the oil cooler and lines and new filter. dont know how to get out of this cept for barrells off and weld the casing or new barrells..... sigh... tits or tyres eh?
Dare I breath the words "Head Gasket?" Let's just hope you didn't clean the oil off enough, and it is just running down from the valve cover gasket or rubber grommets.
Ahem.
Wouldn't surprise me if the head gasket was leaking around the cam chain tunnel. Been there. :(
Isn't a very difficult fix though, intimidating and time consuming the first time, but not awful.
yeah thats what got me buggered. cant see any tell tale leaks leading down to the fin where the oil is sitting. i checked rocker, head and base gaskets, rocker cover rubbers for the bolts just cant find it anywhere. it truly does look like its originating from the bas of the fin. :mad: :dash2: :wacko2:. on the plus side, it has done 42 thousand kays since i bought it and have just had to keep an eye on the oil. will persist to continue to do the same, get the gsx on the road and take the fj to the shed. :flag_of_truce: :mad:
:mad: wow and cos i cant get to work i just got fired :ireful: b*st*rds
Quote from: Kopfjaeger on November 21, 2010, 08:26:52 PM
:mad: wow and cos i cant get to work i just got fired :ireful: b*st*rds
Neil.....Sorry to hear it mate, that sucks!
Harvy
it happens. got a bit sick o working on dirty diesels any how. :wacko1: now off to source that bloody leak!!!! might have a smoke first but..... :good2:
ok. this has got to be the worst week in history. camera is eating batteries and peevving me off. OK. so what i need to kinda know afore i go a rip tear into mine engine is it is possible for an oil galley to blow through? i mean i know its possible but any one had that? its a bit far fetched but i just cannot source it. from the third fin down in the middle of the engine 3 fins down from the head gasket, weeping( actually a LOT) from the fin in the middle of the engine benaeth the cam chain moulding where those two nuts sit. but once again 3 fins down and the head gasket is dry as a nuns nasty. is it possible to crack barrells? i dont run it hot and its always had good oil in it. has anyone used Hylomar on their head gasket? i just dont want to kill it and today is the first ride i have had in 3 weeks or so and it was only round the block looks like a 2 stroke at lights...... goin nuts. its like trying to understand women finding this oil leak :dash2: :dash2: :dash2: :dash2: :dash2: :dash2: :dash2: i will try and at least post some bodgy pics from my phone. :blush:
feck it im parking it and leaving it. :mad: bastard can rot in my shed.
Neil......the only thing I can think of is maybe there is a hairline crack from the cam chain tunnel to one of those studs?
Harvy
your probably right on the money harvey i have drawn the same conclusion it really cant be anything else. sick of it. shes a tempremenstrual ol bitch, you fix one thing something totally unrelated goes..." really? im gunna break now" so i have filled it with oil and its staying in the shed. done. gsx is looking more promising and less hassle all i have had to do is replace rec reg and a starter solonoid, hasnt run for years fired up after 3 tries. think i have found some headers and a master cylinder for the front brakes, so rego and away we go. the fj is lucky right now it doesnt get a 2 dollar tune up :mad: :dash2: :wacko2:
It is probably a crack in the head on the front side.
They can crack on both sides in front. HSR, Hank welds both sides if it needs it or not.
I will try to post a pic to show the fix not a bad joj but the head has to come off.
Bob W
thanks bob that would be interesting to look at see if i can get it done. if you ll all excuse me im going to pull my head out of my arse and stop sulking and get on with it.
copyouslater. and thanks .
Quote from: Kopfjaeger on December 08, 2010, 12:28:08 AM
ok. this has got to be the worst week in history. camera is eating batteries and peevving me off. OK. so what i need to kinda know afore i go a rip tear into mine engine is it is possible for an oil galley to blow through? i mean i know its possible but any one had that? its a bit far fetched but i just cannot source it. from the third fin down in the middle of the engine 3 fins down from the head gasket, weeping( actually a LOT) from the fin in the middle of the engine benaeth the cam chain moulding where those two nuts sit. but once again 3 fins down and the head gasket is dry as a nuns nasty. is it possible to crack barrells? i dont run it hot and its always had good oil in it. has anyone used Hylomar on their head gasket? i just dont want to kill it and today is the first ride i have had in 3 weeks or so and it was only round the block looks like a 2 stroke at lights...... goin nuts. its like trying to understand women finding this oil leak :dash2: :dash2: :dash2: :dash2: :dash2: :dash2: :dash2: i will try and at least post some bodgy pics from my phone. :blush:
There are no oil galleys in the center of the engine. The only oil located in that area will be the oil sling and drain from the timing chain & head. The studs are all exposed about three fins down and if there is a leak from the valve cover gasket it will run down the moisture drain holes and to the front of the engine. Remember the engine is tilted downward at the front so all leaking oil is going to accumulate at the front of the engine.
Have you had the tank off to make sure it is not the v/c gasket or grommets?
Like Bob stated earlier, they do crack near the top of the head on the cam chain kickout. I have only seen this on the engines used in the racecars as the engine is being used as a structural member of the chassis and the extreme heat the engine sees mounted sideway if the car; never on a bike. And since the head gasket is dry that probably means there is no crack.
I have also never seen an oil leak due to a head gasket. The oil galleys are on the right two studs of the engine and use o-rings to seal them. The head gasket has a silver paint sealant applied from the factory, no other sealant should be used.
I will take some pictures of an engine and post them this weekend and maybe you can illustrate on them where it is coming from since you are unable to get any photos.
Randy - RPM
No oil galleys in that location, as randy said.
However yes, galleys can crack through to nearby areas. If you have a 74-77 KZ400 with oil coming from the headgasket area, it's because the rear studs are set too close to a pressurized oil galley. The cases crack a pinch and oil seeps up, along the studs, to the headgasket which isn't capable of holding in the pressure. Was a factory recall on it many years ago, and now the parts are no longer available. Don't ask why I know this, but I've got a summer project to do... :(
nah dont stress randy. the women in me came out yesterday, :ireful: :blush: but having calmed down and stopped torturing small animals i have pulled head out of arse and just going to leave it for a bit. no work cant afford to fix it so rather than sod it up and have another unfinsihed bike im just going to leave it and focus my energies on the gsx. picking up some headers and brake master cylinder, going to strip and rebuild brake calipers today, and give the front end a going over, thanks for the help :bye:
(http://fjowners.com/gallery/1/546_08_12_10_6_07_06.jpeg)
you cant see the drip ( not me the oil) but its the second fin you see down from the nuts. gave them a tweak too just to make sure but its still dripping when running about a drip every 20 secs. rustproofing all my pipes etc. theres no rush anymore i aint touching just pleased to get a pic up. (popcorn) but here is the suzuiki that isnt giving me grief. even if it IS suzuki(http://fjowners.com/gallery/1/546_08_12_10_6_24_16.jpeg) in the shed of death retirement and half finished things(http://fjowners.com/gallery/1/546_08_12_10_6_20_15.jpeg)
Quote from: racerrad8 on December 08, 2010, 08:44:59 AM
Have you had the tank off to make sure it is not the v/c gasket or grommets?
+1
Quote from: Kopfjaeger on December 08, 2010, 06:30:11 PM
(http://fjowners.com/gallery/1/546_08_12_10_6_20_15.jpeg)
I went to the shop and shot a couple of pictures after work and they should be posted shortly. The area you are describing is open to the rear of the engine.; which I demonstrate in the photos.
You need to remove the tank and look at the valve cover & grommets like I said before. If they are dry the since the area you are describing is open, I would venture to say you have a leak at or near the timing chain tensioner which bolts directly upstream from the oil drip. Take off the carbs and the heat shield and see what you have coming from that area.
I believe this oil leak is going to be a simple fix since it doesn't appear to be coming form the head or base gaskets.
Randy - RPM
<edit> Here are the pictures from Randy
I pulled an oil barrel to get a picture. As you can see the cam chain passes through the center boss.
(http://fjowners.com/gallery/1/49_09_12_10_12_58_08.jpeg)
I shined a light through to the back of the cylinder, this is the path of your oil.
(http://fjowners.com/gallery/1/49_09_12_10_12_53_58.jpeg)
The timing chain tensioner is probably going to be the leak. It bolt onto the flange and will leak forward, right down those fins if it is leaking. The is also a chance it could be the valve cover as well.
(http://fjowners.com/gallery/1/49_09_12_10_1_03_00.jpeg)
(http://fjowners.com/gallery/1/546_08_12_10_10_13_25.jpeg%5Bimg%5D)http://fjowners.com/gallery/1/546_08_12_10_10_17_56.jpeg (http://fjowners.com/gallery/1/546_08_12_10_10_17_56.jpeg)[/img](http://fjowners.com/gallery/1/546_08_12_10_10_17_56.jpeg)(http://fjowners.com/gallery/1/546_08_12_10_10_11_33.jpeg) i ll give it a check. (popcorn)
humble pie anyone? got lots to share :blush: :blush: :blush: :blush: :blush: :blush: :blush: :blush: :blush: :blush: :blush: :blush: :blush: :blush: :blush: :blush: :blush:
Quote from: Kopfjaeger on December 08, 2010, 10:40:42 PM
humble pie anyone? got lots to share :blush: :blush: :blush: :blush: :blush: :blush: :blush: :blush: :blush: :blush: :blush: :blush: :blush: :blush: :blush: :blush: :blush:
pretty good resource we got here aint it ?
enjoy your pie brother...and while you're snackin i'll go ahead and say the obligitory.. THE FJ is way tougher than that suzuki.... any day of the week ....
....just sayin' KOokalooo! :good:
ok. fingers crossed. removed cam chain tensioner made new gasket .03 gasket paper, cleaned out threads .( m6 x.1) bit of gasket goo, ( less than a smear) tensioned back in cleaned engine, cleaned carbs wrestled the rear subframe back in ( :ireful:) and will hook up wiring tomorrow ( give everything a chance to gel .... yes im paranoid if you havnt worked that out yet) got a resistor block (ballast) for the rear LED s that used to be on it, gunna take another daring chance ( yes yes i know 2 in 1 week.... WHAT A DEMON!!!) and remove it, cleaned all the rear swinging arm and suspension. if this was the problem, ( i really hope it is) than humble pie never tasted so good............. and yes the suzy is not a patch on the 1200, i know that, but i do like 750's and its coming together nicely and not giving me troubles (yet).
THANK YOU ONE AND ALL AND SORRY FOR BEING A TOUCH MELODRAMATIC AND A WANKER..... ( paranoid about oil leaks, had one bike eat the bottom end and another the top.... but they were kwakas) :sorry:
Quote from: Kopfjaeger on December 09, 2010, 05:18:07 AM
ok. . removed cam chain tensioner made new gasket, tensioned back in cleaned engine
Hey man did you reset the tensioner? If not you must do so before running the engine! I think :shok:
oh hell yes. :good2: much easier than the kwaka ones those ones are on the side of the enigine and are a ,... sheesh... like the fj in the sense its mechanical but ... to install it... have to hold it in your hand and turn the worm screw in the middle to pull the plunger back in till 10 -15? mm shows . THEN with one hand keeping the screwdriver in place the other holding it still you have to slide it in to the housing and then get the 2 x6 mm bolts in and seated tight . and THEN let go the screwdriver and WHACK!!! tensioned. tricky. the fj was a darn site simpler. with the exception of removing the rear that was a bit of a chore but i manged to keep the skin on my bits o meat at the and of my arms . Normally airboxes remove skin for me and turn the air blue. i unfortunatly dont have hands that have fingers that start at the elbows and are triple jointed :crazy:
Quote from: Kopfjaeger on December 09, 2010, 05:18:07 AM
............ and yes the suzy is not a patch on the 1200, i know that, but i do like 750's and its coming together nicely and not giving me troubles (yet).
THANK YOU ONE AND ALL AND SORRY FOR BEING A TOUCH MELODRAMATIC AND A WANKER.....
No worries mate. I think it's safe to say that, in one time or another, we have all felt that way. Kudos for reaching out.
When (not if) you get into problems with your Suki, I hope you have a forum you can turn to like ours....
Like Frank said, we have some very smart folks hanging out here.......Once again, thank you Randy! Cheers. Pat
Man, you guys are lucky. My FJ at no point ever leaked from just one point! The countershaft, head gasket (pretty sure there, the gasket had been reused more than once and the tensioner wouldn't account for the pattern of oil on my motor), the CCT also of course, the valve cover grommets... and that's just the oil leaks! Oddly, I don't think the oil filter area ever leaked, but the clutch fluid probably kept that clean....
Some FJ's have had much harder lives than others. My top priority for my rebuild was no more leaks!
sigh. calm now. but its not the cam chain tensioner. its dry as, no oil marks around it. still leaks same place im stripping it now and taking pics :morning2: whats the expression" doesnt kill me makes me stronger" wheres mr coffee? :morning2:
:cray: I was a little sad when you (thought) found the leak, I thought all the great entertaining posts were going to end.
So now I am happy, continue on (popcorn)
your just lucky you got the trooper as an avatar.....chuckles. cant go rank at someone who loves the maiden.......just wish i could play as good as mr mcbrain..... i will do my best to keep you entertained :dance: :greeting: :shout: :yahoo: :blush: :dash2:
(http://fjowners.com/gallery/1/546_09_12_10_9_21_45.jpeg)(http://fjowners.com/gallery/1/546_09_12_10_9_24_58.jpeg)(http://fjowners.com/gallery/1/546_09_12_10_9_31_08.jpeg)
And I think the question Mr Conlon is not wether there is a suzuki page that can be as useful as your esteemed selves , but wether in fact they could put up with my annoying habits :D :music: :music: :music: :music: :music: :ireful: :ireful: :blush:
"where's Mr. Coffee?"
Kopfjaeger, you seem to have found him. Up the Irons!
rock on. only missing live after death......( not going to mention judas priest. nup.not at all. not even twisted sister. dio? nahhhh spinal tapp any one.....???)
Quote from: Kopfjaeger on December 10, 2010, 09:55:45 AM
not going to mention judas priest. nup.not at all
:good:
(http://cover7.cduniverse.com/MuzeAudioArt/110/115170.jpg)
Those hoses look a little wet
There not leaking are they?
(http://fjowners.com/gallery/1/546_09_12_10_9_19_01.jpeg)
im pretty sure they arent.( but ive shown my diagnostic skills and knowledge of this bike are crap). what i did last night was go over and over my tensioner , new gasket again retensioned and cleaned cleaned cleaned. went riggghhht over everything, took all the fairings and absolutly everything off to engine and frame and wheels only, used a loctite gasket goo instead of highttemp atv sealant( blue sensor safe stuff) cleaned and retapped threads loctite primer and then thread locker .( i know its going to be a pain in the arse to get out .... but ill worry bout that later), 3 cans of degreaser on the engine and then a good ol crawl around and over the engine withtorch lights and mirror, the ferrule in the airbox( top bolt) spun in the housing, broke it out, hole in the airbox now patched ( my neighbours are learning new words all the time.... this COULD BE why ol mate next got up to mow his lawn at 7 am today..... but i digress) its back to only having the fairing and tank off, going to put the tank on in half a cup o coffee or so and fire it up and well see.......... :blush: i even followed the destructions for the loctite and let it cure for almost 24 hrs!!!!!!!...... and as for the screaming for vengence.....chuckles got that... actually was interested ... you know the song they all went to court over? the i ummm song they reckoned caused suicide? i always thought it was " beyond the realms of death" on stained class..... but.... it s actually the song " better by you better than me" go figure :wacko1: i still reckon spinal tapp got it dead right......... :good2:
:dash1: :dash1: :dash1: :dash1: :dash1: :dash1: :dash1: :dash1: :dash1: :dash1: :dash1: :dash1: :dash1: :dash1: :dash1: :dash1: :dash1: :dash1: :dash1: :dash1: :dash1: :dash2: :dash2: :dash2: :dash2: :dash2: :dash2: :dash2: :dash2: :dash2: :dash2: :dash2: :dash2: :dash2: :dash2: :dash2: :dash2: :dash2: :dash2: :dash2: :ireful: :ireful: :ireful: :ireful: :ireful: :ireful: :ireful: :ireful: :ireful: :ireful: :ireful: :ireful: :ireful: :ireful: :ireful: :ireful: :ireful: :ireful: :ireful: :ireful: :ireful: :ireful: :ireful: :ireful: :mad: :mad: :mad: :mad: :mad: :mad: :mad: :mad: :mad: :mad: :mad: :mad: :mad: :mad: :mad: :mad: :mad: :mad: :mad: :mad: :mad: :mad: :mad: :mad: :mad: I think i found it a pin hole in the front of the cam moulding just above the second fin. can get end of scribe about 1mm in and the engine is clean enough to see where its coming from. taint the coming from the back. all this because i originally cleaned it all over to make it pretty cos i got jealous of all the shiny bikes. bugger eh? i think its a case for contact cleaner and a bit of quick steel. although i do have some high temp epoxy resin they use for sealing electrical cables in underground equipment...... feck it coffee and (http://fjowners.com/gallery/1/546_10_12_10_6_11_36.jpeg) a ciggy are in order. and then check for more holes..... :cray: :cray:
and listen to BLACK SABBATH ...." never say die" nice and loud to repay the lawnmower this morning.
3 ways i can do this. all have merits. i throw the options to you wise gentlemen of fj land. 1. bit of stag gasket paste.( wont really get into engine but may flake off) 2. loctite quick steel.( may work into engine and is also grainy? in finish may still weep) 3. drill out to small set screw size tap and insert set screw with loctite.( best option cept for the operator ). what would you guys choose?? i used to be indesicive but know im not so sure......... :scratch_one-s_head:
I have had pretty good luck with JB weld (and the loctite equivalent) seem like the same stuff so the results have been good. I filled a hole 20 times bigger than that in my KX cases. Sand and clean it up pretty good so it will adhere well, do a couple coats first one really really small, second really small.........etc. as needed.
I can't see this hole your talking about from the picture? is it that black speck or the rust looking area?
the rust looking area. took me 10 minutes to find it...( used up my vocabulary of swearing... so actually got to concentrate) that little speck in the middle of the rust area is the point its originating from. tank off bike running on float bowls and me under the bike with a torch. those headers get warm...( hence the red dot on my forehead.) :smile:
Wow Neil, well done mate.......that is barely visible (and with my eyes it would not have been found at all!).
I would personally go with option 3, with a twist - a cap head screw with a fibre or copper washer under it.
I bet there was in inclusion in the alloy when the barrels were originally cast.
Harvy
(http://fjowners.com/gallery/1/546_10_12_10_9_24_43.jpeg) Thats a better pic... Yeah Im just a bit pleased that the paint wore off or I never would have found it !! I'd just like to say thanks again to all for helping , and i hope i provided good entertainment...( trust me I'm always laughing at myself... so its nice when others join in!!) :good2: just gunna plug it with quick steel till I get access to the right gear, haven't got a small enough tap, and I'd like to use an inhex grubscrew. :hi:. Thank you linesman , thank you ball boys copyouslater!!!!
Wow - I wonder how the hell that happened? You're sure they go all the way through right? Bad casting originally? I can't see how that could happen...I need some enlightenment.
Been following this oil leak posting for a while now. I remember seeing a story on Pashnit.com about a 2ND gen bike loosing a large chunk of metal thru to the cylinder wall, exposing the piston. He was still able to ride the bike to the next town to get a UHaul, pouring oil all the way. I think I have seen other stories about frailties in the casting of these barrels. But the FJ. being of sturdy stuff, never stranded their master over this. :good:
Has anyone else heard of any issues with this from other sources?
Merry Christmas,
CraigO
90FJ1200
Quote from: Travis398 on December 10, 2010, 07:58:59 PM
I have had pretty good luck with JB weld (and the loctite equivalent) seem like the same stuff so the results have been good. I filled a hole 20 times bigger than that in my KX cases. Sand and clean it up pretty good so it will adhere well, do a couple coats first one really really small, second really small.........etc. as needed.
I can't see this hole your talking about from the picture? is it that black speck or the rust looking area?
+1 on the JB Weld. Never failed me yet.
CraigO
90FJ1200
Had a similar experience with a small inclusion in a brass freeze plug on an old V-8. The small steel inclusion rusted all the way through and caused a cooling leak. Almost never found that leak.
Yeah. All I can put it down to is a bad casting. Unless .... at a wild stab in the dark on the edge of fantasy all I can think is a rock? But nahhhh.... illogical and 1 in a million. Has to be bad casting. I had chatted to a bloke on the Yamaha IT forum a while ago ( long whle ago) and yes his 1100 blew a chunk out like you say and yes it still got him home ish apparently. Have also heard that the best thing to do is to stay away from jap big bore bikes as "their crankshafts are like rubber"..... couldnt really say myself this is the first major problem i have really had with it, everything else has been a fix it when it really bothers me thing....and this is my 1st "big bore" bike i spose the rest have been 3/4 and litre bikes
Quote from: fj1289 on December 10, 2010, 11:07:57 PM
Had a similar experience with a small inclusion in a brass freeze plug on an old V-8. The small steel inclusion rusted all the way through and caused a cooling leak. Almost never found that leak.
Must have come in the same batch that I had. Same experience.
If it was a rock, you would think that maybe there is metal floating around in the sump, assuming it busted a piece out inside the tunnel.
Harvy
Bad castings aren't entirely unheard of, actually. Does happen. Don't know that is what I'm seeing in the picture, but meh, doesn't matter, it's a hole is a hole is a hole, y`know?
JBweld that sucker (don't use the fast stuff, use the normal slow setting stuff) after really roughing it up good. Bet you end up fine with it (I threw a chain around my countershaft and the seal for the clutch pushrod is now maintained by JBweld... and tha'ts a pressurized galley! Good prep and it's not a problem in the slightest).
wow andy sounds like youre fj is held together with jb weld and cable ties.... :sarcastic: used degreaser then the (ahem) can of flaw check high strength contact cleaner....(melts paint off ... pretty good stuff.... also good for spiders :) its better than moretein....) then set to with a small file (handy having the ol model kit supplies close by) put loctite quick steel on last night. going to check it this morning. give it a bit of a rub back and see if it needs more. :good:
just a heads up, seem to have a problem with the loctite metal. put it on about 11 am yesterday, 10 :45 am sunday now still hasnt cured so cleaning it all off and grabbing some of your jb weld. Dont think i applied it wrong...( blonde yes drummer yes ) but i would have thought it would have semi cured at least. any hoo not stressing just a small setback. thinking i should have known better !!! as a bit of an aside re loctite....when in tech for 3rd year we had the loctite man come to school(!) and give us the run down on loctite the anerobic glue of the future!!! chuckles i can remeber him distintcly showing how to apply loctite thread locker.... brought little nuts and bolts for us all.... dont let the tip touch the metal cross contamination.... now screw your nut on.... in about however long it was it will cure and be gold.... can remeber at the end of the day me and about 2/3rds the class unscrewing nuts by hand.... chuckles.... it is good stuff but when i have to use thread locker i prefer to use bearing retainer it holds better. but thats just me.... any hooo off to get some jb weld or kwiksteel!!!!!!!
no leaks thus far, going for a test ride round newcastle. cheers everyone. :good2:
ok all went well no leaks no drips no mess . :good2: rode it round town in traffic, it got pretty hot, but it is a warm muggy day here and was in traffic. take her for a long run maybe tuesday. been so long since ive ridden it ( pretty much since the start of these posts) ive forgotten how hot they get. no rattles or bangs ( clutch is still noisy) just a bit of heat. i ll wack some feresh oil in'er and see how we go. cant say thanks enough ladies and gents. hope it was amusing and i wasnt too much of a pain in the arse. cheers
neil
After 26 years of futzing with FJ's, That had to be the most difficult oil leak problem I've ever seen.
A casting flaw? I don't see any other explanation, unless someone shot you with a pellet rifle or took a ice pick to your motor.
Major Kudos for staying with it, identifing and solving the problem.
You did remarkably well considering I don't think I could have gone thru that, and stayed sane. :good:
Quote from: Kopfjaeger on December 11, 2010, 10:49:49 PM
ok all went well no leaks no drips no mess .
That's great news, lets hope it stays that way. I would have never guessed that one, even though you kept saying it was leaking in the front between the fins.
Maybe we should have listened better, as you know diagnosing the problem is often harder than fixing it.
Quote... as you know diagnosing the problem is often harder than fixing it.
Yeah, especially when you can't personally witness the phenomenon. Good job, Neil. I'd have given up long ago.
thanks fella's. that means a lot. seem to be a bit lucky at the moment..... managed to swap a dt 175 carby and 2 old dirt bike tyres and a suzuki dr 250 tool kit ( plus a few small items) for a full set of 4 into 1 good headers for the suzuki gsx, brake master cylinder and an r6 end can all in pretty awesome condition. i tell ya this bloke is gold.... showed me round his joint.... various IT 465's and 490's 2-3 RD 250's and 350's ( and spares to bild about 6 of them).... and the cream for a stink wheel... a KH 250 triple with feck all on the clock. managed to secure 2 1980 DT 175's and an early model DT ( i think 78???) for about 500 bucks!!!!... projects projects projects :good2:... and once again i appreciate all of your input because these are things i didnt know about that i do know..... keep the rubber side down.
cheers
neil
So, spare me 5 pages of re-reading. Was the oil leak from a casting defect or the cam chain tensioner gasket?
DavidR.
David, looks like Neil had a casting flaw, or a pissed off neighbor with a ice pick. See the hole?
(http://fjowners.com/gallery/1/546_10_12_10_9_24_43.jpeg)