The Monkey visits Randy at the RPM shop

[FJmonkey]

Warning: This post will be long and filled with many images and my diatribe of events from two days of visiting Randy and his sons.

Last Monday I had the pleasure of riding into Randy's shop for some overdue diagnosis, repair, and upgrades. I was not disappointed with my visit.

I rolled in to the shop a little after 2PM and was ushered directly into the shop and its checkered tiled floor, Very cool. We got my bike up on the lift and started the tear down to see where I was leaking oil.







Then Randy found my oil leak.... 



This crack most likely happened 14 years ago when I low sided and dropped my FJ like a rock (I highly recommend the Renntec bars to protect from this problem (RPM is my source for my current set) . It got worse over the years till I got sick and tired of my over oiled and grimey bike...

Time to pull the engine and clean the years of oil and road grime off to see the real FJ...









Now my FJ is cleaner than ever before. Some Gunk engine cleaner, Simple Green (a gallon or two), scrubbing with brushes, a power washer (twice). And WOW!!! I can see my bike again...

Now to the real gritty part of this post.... The die grinding of the case to expose the offending CRACK... Say NO to CRACK!!!



After the die grinding it helps to apply heat, this causes the oil to weep and expose the crack. Important note: Synthetic oil really sucks for this process. Dino oil can be burned out, synth will not burn... 



Then get a proper TIG welder to fuse the cracked case back to a Not Cracked condition.





Then I opted in for a few upgrades.

Heated grips...


Here is how I used the old reserve switch location on my 86'....


The connector for my alternator was cooked, no pics, just cut and replaced with spade connectors. I most likely missed some other details and I hope Randy can fill in any important details I missed... Hint...Hint...



Randy and I had to drop and install my engine twice in less than a day and a half, the crack in my case was tricky and made a wicked turn (hence the need to drop my engine twice). Randy was a gracious host and awesome service provider during my visit. During the second drop Randy timed the progress. We started at 5Pm and had my engine on the weld bench by 5:21PM. Just Randy and I. Then we got the welded engine back in in 30 min on Wednesday.

My ride back home was pleasant with my new heated (foam) grips from RPM.... My engine is leak free and I am a happy camper with a clean FJ and some really good experiences with Randy at RPM.

My thanks to Randy at RPM and both of his sons to make my trip a real adventure and FJ RPM win...

[stua1959]

I wish we had a Randy where I live

[aviationfred]

Mark,

Great write up to find your oil leak. Definitely a difficult place for a leak to be detected.

Awesome photos of the Power Ranger machine getting some love.  

Fred

[movenon]

Nice write up Mark  .  I have the same heated grips.  I had to resolder the connection on the throttle side to the element.  Then secured the wire to remove any pulling on the joint.  Soldered and taped the wire, then reinstalled the grip. works great now.

Glad the crack was easy to fix. Just say no  .  

I am about 2 projects away from pulling my engine so it was of great intrest to see your photo's.  Stay well and out of the dirt  
George

[TexasDave]

Very nice post. I too had a very nice ride home after Randy improved my FJ. Randy is a great guy and a professional mechanic. Dave  

[FJmonkey]

Very nice post. I too had a very nice ride home after Randy improved my FJ. Randy is a great guy and a professional mechanic. Dave  

Dave, Randy had good things to say about your visit as well. Perhaps we can met up during a ride some time....? Being between jobs, perhaps I can travel and meet up with a fellow FJ rider....

[FJ1100mjk]

Your thinly-veiled attempt to make other here jealous has worked. At least on one person 

Considering that you had the engine out 2X, why didn't you split the cases and fix that second gear issue that you've been hobbled with for years? I know you're out of work (been there, done that), and perhaps economics played a role.

P.S. You don't have to answer, I'm used to it here. 

[FJmonkey]

Your thinly-veiled attempt to make other here jealous has worked. At least on one person 

Considering that you had the engine out 2X, why didn't you split the cases and fix that second gear issue that you've been hobbled with for years? I know you're out of work (been there, done that), and perhaps economics played a role.

P.S. You don't have to answer, I'm used to it here. 

Cost was the factor in not fixing my second gear issue. However, having dropped and installed my engine twice in as many days has given me confidence. It is not difficult or complicated and no special tools are required. The lift table made things much easier but not required, the only special tool I think is needed is a small floor jack to lift and lower the engine while the bike is on the center-stand. When its time to fix second gear and refresh the rings and whatever else the girl needs, I know I can pull it out and get the work done. Or ride back up to Randy's to do it. After my first experience at RPM I am more likely to do that for my rebuild and possibly get his EFI system installed. That would be some real Kookaloo for me.

[Tiger]

Oil leaks can be a real P I T A...to find and sometimes, to repair Nice write up to document your 'find & fix' Mark... not to mention saving the Cali climate 

John.

[FJmonkey]

Oil leaks can be a real P I T A...to find and sometimes, to repair Nice write up to document your 'find & fix' Mark... not to mention saving the Cali climate 

John.

This leak plagued me for years but was not big enough of a leak to consider an emergency, so I just dealt with it and added oil more often than normal. I finally got tired of my FJ not being house trained and pissing everywhere I stopped. The oil went everywhere and collected a serious amount of dirt and grime, I estimate an additional 2 pounds of crap stuck to case. I had the time off and Randy said come on up and we will fix it. I rode the 6+ hours (300+ miles) and within 30 minutes he found the crack in the case. About 20 min after that he had a plan to drop the engine and weld the case without splitting the case. This saved me a lot of money. Since Randy has done this before with success it was an easy call. As I said before, Randy was a great host, the motel 6 near his shop was not expensive and better than most motel 6's I have stayed in. And I am sure the tree huggers might send me a Christmas card this year....

[Steve_in_Florida]

Mark,
You had the right mix of things available to solve your problem. Very nice fix.

I have need for some valve cover grommets for my own oil leak on the `90. RPM is about to get some more of my FJ budget!

Thanks for posting the pictures. Why no shots of the Motel 6 with the FJ in front? ...or in front of RPM's shop? ...or a BEFORE shot, with the FJ over a puddle of oil?

Remember, the background can help tell a story.

Steve

[FJmonkey]

Thanks for posting the pictures. Why no shots of the Motel 6 with the FJ in front? ...or in front of RPM's shop? ...or a BEFORE shot, with the FJ over a puddle of oil?

Remember, the background can help tell a story.

Steve

Steve, to answer your questions: My FJ never made it to the Motel 6, I pulled in to RPM on Monday and was ushered directly into the classy checkered tile floor like royalty. My FJ was given proper treatment and respect while I had to endure the sub-standard overnight conditions at a motel (but not a bad one, it was decent). No shots outside of RPM as the shop has no marque' or store front, not very exciting. The exciting stuff happens inside where the talent is. 

Is this not enough oil under my FJ?



I enjoyed my time with Randy and his sons, I look forward to my next visit and ride with him.

[charleygofast]

Very nice report Mark, kinda brought me right there. Nice to give her a proper cleaning too! I tell ya, you Cali guys got it made (or any southerners)...year round riding, and R.P.M not far away! (BTW...nice tidy shop Randy!)Just one more WI. winter and "Operation Snowbird" takes effect. Enjoy many leak free miles and stay on the tarmac!                   Cheers!                                                                                                                                                                                                     Charley.

[Firehawk068]

Great post Mark.....................It amazes me that Randy found that crack underneath all that grime. or even knew where to look........

Nice Job!

[FJmonkey]

Great post Mark.....................It amazes me that Randy found that crack underneath all that grime. or even knew where to look........

Nice Job!

Randy just followed the clean oil as he went up the engine. The oil leak left cleaner trails, Randy said the detergents in the oil clean off the grime as it drips down the engine. Once we saw that the oil leak was as high up as the starter. Then he verified that the starter was not leaking. And I am sure it helps that he has seen cracks in the same place on other engines he has fixed. So his experience and knowledge was exactly what I needed to get it done right. He also found and fixed other issues like the alternator connector, it clearly over heated and melted the connector. This may have left me stranded if not found and fixed.