Think Ive blown a gasket

[FJTillDeath]

And I havent heard anyone say "DONT BUY THE NEW SYSTEM" so Im assuming that I should go ahead with it? since I only get the rest of my pay on  fridai I will only be able to order on saturday so if someone can tell me Im an idiot and not buy the system for a valid reason please tell me..As I said the advantage of getting the new system is that it would be NEW-therefore no problems and covered by a garuntee just incase.

The gaskets dont seem like an expensive job and it doesnt look Im at too much risk just yet. With the exhaust however I am really starting to worry if the bike will get home each day now. I mean it still rides, but it struggles to start, it bogs down when cold, it is far less powerful. It soiunds worse than a tractor with a lawnmower chopping through shreds of metal. BUT the worst byproduct so far is the heat. The engine is atleast 3 times hotter than I normally feel. AS an example, I took the bike home from work (slowish 20 min ride - not too much traffic) got home and parked the bike outside like normally and could feel the heat saunaring off the engine all the way to my neck - air temp was ony 20 degrees C - not hot at all. And 6 hours later (at 12 midnight) I remembered to put the bike cover back on. Went outside very cold proceeded to put the bike cover on and could still feel the heat from the engine-not hot but still there. Normally it takes just 2 hours for my bike to fully cool down at rest so that you can touch the engine and feel cold metal. So yes this makes me worry just a tiny little SHITLOAD

[oldktmdude]

  Take the bike to another mechanic and get a second opinion. You might save yourself alot of money. You haven't described the exhaust problem, to us, in terns that any of us can understand. You need to tell us EXACTLY where it is leaking and what needs WELDING to fix it. Forget about your oil leak for a while, that's only complicating your post about your exhaust. There is nothing on your exhaust system that can't be repaired by welding, so there is no need to buy a new system, especially if you don't have enough money.   Pete.

[FJTillDeath]

The dealer mentioned that it was the headers that needed to be welded. They told me it would cost 850rand (about 110dollars) and that it may only last 6 months becuase of heat from the engine. I may have understood what they said wrong, but its the headers that need to be welded and the gaskets in them that need to be replaced.

[FJTillDeath]

Quick question for Andy> I had a quick squiz at the file section with mods you can do to your FJ, I read there something about larger nuts or something? and the comment was that if a proper sealment wasnt used it would cause the oil to seep out - something like that. Is it possible that is the case with my FJ? I know that a couple years ago the engine was rebuilt, but dont know anymore detail than that as the previous owner is dead. Rest his soul.

Not to get off topic or anything, can somebody please provide me with a link to a 1349cc thread, how to get it etc? I would really like to make a model replica of the race version I seen with the full fairing, obviously it will take time to do and money but its something i dont mind waiting for.

I made a plan and I have enough money for the complete exhaust system so I can do it. Like I said I would prefer a permanent fix rather than something that may brake later again anyway. If there is more information needed to ask something like pictures, I will take them, but please tell me exactly what to take a picture of - maybe even show me a pic - I know im not really in a position to ask for something like that but then I know for sure what I need to do and wont make myself look like an idiot...

[RichBaker]

4-1 sounds like a complete aftermarket system..... but, if it's only leaking at the gaskets, it should only require new gaskets.  A couple hours work unless there are major complications, such as broken studs.....  In all, shouldn't be 12 hours work involved.

[FJTillDeath]

4-1 sounds like a complete aftermarket system..... but, if it's only leaking at the gaskets, it should only require new gaskets.  A couple hours work unless there are major complications, such as broken studs.....  In all, shouldn't be 12 hours work involved.

The dealership did mention that if they had to replace them or something of the sorts it would "disrupt the system" and that would require the whole of it to be replaced. So there may be broken studs.

What I do know is that my dealer disagrees with everything the guys on this site say. I choose to believe the people here as they have specific experience with the FJs

[andyb]

Quick question for Andy> I had a quick squiz at the file section with mods you can do to your FJ, I read there something about larger nuts or something? and the comment was that if a proper sealment wasnt used it would cause the oil to seep out - something like that. Is it possible that is the case with my FJ? I know that a couple years ago the engine was rebuilt, but dont know anymore detail than that as the previous owner is dead. Rest his soul.

You're not listening.  Yes, you can go to a stronger nut for the engine in an effort to provide additional torque on the head gasket and base gasket, which is undoubtedly unrelated to what's leaking (the valve cover and cam cap bolt gaskets).  You can check the torque on your head studs with a torque wrench, which should have been done shortly after the motor was rebuilt and run.

Not to get off topic or anything, can somebody please provide me with a link to a 1349cc thread, how to get it etc? I would really like to make a model replica of the race version I seen with the full fairing, obviously it will take time to do and money but its something i dont mind waiting for.

Replace cylinder liners, bore to size, clearance upper crankcases as needed, assemble.   Fix anything else you want while you're in there, set things to whatever spec, etc.  Same as any overbore that requires new liners.  If you want to send things out for nikasil plating and cryo treatment or whatever you feel like spending on, go for it.

made a plan and I have enough money for the complete exhaust system so I can do it. Like I said I would prefer a permanent fix rather than something that may brake later again anyway. If there is more information needed to ask something like pictures, I will take them, but please tell me exactly what to take a picture of - maybe even show me a pic - I know im not really in a position to ask for something like that but then I know for sure what I need to do and wont make myself look like an idiot...

Gosh, how about the area that is leaking or is damaged?  That'd be a pretty logical first step.

[FJTillDeath]

I thought that was covered in the first post? if you mean take the engine apart thats something I can only do on the weekend

[FJTillDeath]

I realise I may not be supplying enough information, so tonight I will tear into the FJ and take a picture of everything that looks cracked/ damaged etc starting from the plugs and eventually working my way down the exhaust. Are there any specific tools I will need in order to take the these parts apart and is there anything i need to be careful for

[DailyDriver]

I thought that was covered in the first post? if you mean take the engine apart thats something I can only do on the weekend

I think what is being asked is more detailed pics of the whole area in question. Fortunately, I'm just finishing up replacing my cylinder cover gasket and bolt grommets myself, using the opportunity to check and adjust the valves. New gasket in place. Below are a series of pics as an example. You need to use my example and take some pics of your bike in the same general area and post them here. Then those in the known on this site can study them and hopefully determine what might be the problem with your bike and offer some advice. Good luck.

Pull off gas tank and look at cylinder cover. Mine is cleaned up now but it was full of caked on oil.


Pull off your fairing scoops and you can get a look at the front of your cylinder cover gasket. Is there evidence of an oil leak either from the gasket or the bolt gromets?


Take some pics of around the exhaust header. Take several from different angles as the camera only shows a narrow field of view.






Get a close up if you can.


Hope this helps.

[Arnie]

STOP !!!

You've now got a number of people trying to help you, and every one of them thinks your problem is different.  Perhaps one person has got it right, but which one?

Taking pictures will probably not help.  If you have a gasket problem, it is unlikely to be visible, so pictures will not show the problem.

For any of us to help you we need to actually know what the problem is.  That requires us to ALL be speaking the same language.  Sorry to say, but you are the one who (at this time) does not yet know the correct technical names for things.  That might not be so bad, but you take terms you've heard and mis-apply them.  Hence, confusion for us all.

The only gaskets that might require 12hrs of labor to replace by a trained mechanic would be the head or base gaskets.  As distrustful as I am about dealers, I doubt anyone would try to charge you 12hrs labor for an exhaust gasket or a valve cover gasket.

If you can slow down enough to thoroughly and accurately describe your problem (which cylinder(s), what its doing (missing, rattling, blowing smoke, not firing, leaking oil and from where, oiled plugs, blistered plugs) we can try to help.

Notes: #1 cylinder is on left of the engine when seated on the bike facing forward.
#2 cylinder is next to the right inboard of #1 when seated on the bike facing forward
#3 cylinder is next to the right of #2 when seated on the bike facing forward
#4 cylinder is on the right end of the engine when seated on the bike facing forward  

If you have a shop manual, read it.  This will help you to name items correctly.
If you DON'T have a shop manual - get one !!!

If you believe you have multiple problems....
Try to describe them separately and work on ONE at a time.

Take the time to correct spelling and use punctuation.  
This helps others understand what you are describing without guessing.

Separate your written thoughts with a blank line.  It lets us know there is a break.

Arnie

I realise I may not be supplying enough information, so tonight I will tear into the FJ and take a picture of everything that looks cracked/ damaged etc starting from the plugs and eventually working my way down the exhaust. Are there any specific tools I will need in order to take the these parts apart and is there anything i need to be careful for

[SlowOldGuy]

THANK YOU ARNIE!

More information that's not related to the problem(s) is just NOISE.

I got confused several pages ago and gave up.

Do what Arnie says.  Separate your problems from other stuff you want to do.  Otherwise everyone will get confused by the multiple topics,  then frustrated at the differing conversations, and finally give up.  For 3 pages now you've been told to replace the cam cover gasket and grommets (I think this is the original issue).  But now you've gone off into several different directions with WAY too much information (noise!).

Start over.

DavidR.

[FJTillDeath]

First of all, thanks for all the clearing up. Thanks for the illustrated guide of what I need to take pictures of. I unfortuntaely only got to read the post now, but I think I still took adequate pictures and even a video.

However to make everyones life easier I will discontinue this thread and start 2 more up with the exhaust header issue and the leak issue providing (hopefully) enough adequate and usefull info for the guys trying to help me.

Many thanks
Jesse

[Dan Filetti]

If I can do the replacing of the gaskets myself I am then assuming that it being a 12 hour job is bullshit?

From where I sit, this was the dealer essentailly being indirect about telling you they did not want to do the work.  This way, if you did actually say, 'yeah OK' then they make a tidy profit on the PITA job.  Find someone else who does want to help you, and will be reasonable about estimates.

Dan