What did you do to your bike today?

[Fudge]

installed new PR2s and .80kg fork springs with 12wt oil.  Balanced the carbs.

[carsick]

 Rode it naked. No, wait, that doesn't sound right, how about sans fairing. Rode around the parking lot at work for half an hour to check out my GSX-R rear wheel swap, braided lines, new chain, and blue dot calipers. Managed to scuff in the tires in good shape and clearance the peg feelers. Seated the pads in, resisted the urge to do wheelies past security cameras. Everything works! Very pleased with mods so far, now for the mileage to truly test their worth. Fork overhaul and FZR front wheel are next. Feels great to be rolling again!
Doug

[waricle]

Harvy,
         The FJ starter drive is susceptible to loosing spring tension on the one-way clutch. When looking at the exploded view, the problem parts is #8. http://www.bikebandit.com/houseofmotorcycles/showschematic/m7148sch217477

These springs are about as fine as the spring within a retractable ball point writing pen. The use of some synthetic oils, thicker oils and/or a lack of changing the oil can also cause these rollers to slip and not allow the starter to turn the engine. There is no easy repair as the bottom of the case would have to come off to service the springs. Previously, I have never replaced the springs, but have chosen to simply stretch them to increase the spring pressure when doing rebuilds.

Since the introduction of the XJ model engine, Yamaha change this three ramp/roller system to a one-way sprag which has eliminated the problem all together. That is now what I install into every rebuild I do so that problem never leaves anyone having to bump start the engine.

Randy - RPM

Randy, yes, we were wondering about the oil part of the equation.
Pete is using Castrol Edge 10-60 fully synth, which to me seems too extreme at both ends for Queensland conditions.
I don't want to buy into another oil thread here, but I personally use 20-50 dyno, and with just shy of 100,000kms, I have not had any starter problem - touch wood!

Thanks for the tip on the XJ engine update.......when the time comes that's a good way to go.

I'm sure Pete will see your response........ he is putting together a bit of a list of parts.... so he will be in contact.

Still waiting to hear some good news from you about your back mate....... its a bugger when something so small can change your whole perspective on life....chin up mate!

Harvy

Well, after Harvey went to all the trouble of bringing and helping fit the starter ( and much appreciated help, Harvey) and bled the clutch I arranged to go for a ride Sunday.
Didn't happen. The starter whirred but wouldn't catch
This was about 7:30 am and about 10C.
I waited till 10:00 am when in warmed up and tried it again, it fired.
Today I went for a ride, picked up some 10w 30 synthetic - I don't want to risk trouble by changing to mineral- and changed the oil.
So far so good. Starts easily.
Early tomorrow morning will be the test.
I had a ride on Harvey's bike Saturday and it seem to have more of everything, brakes, suspension, response and handling. A nice ride.
I can see why the mods are so popular.
Pete

[waricle]

IT STARTS COLD!!!!!!

[Harvy]

IT STARTS COLD!!!!!!

Excellent Pete!

Randy was on the right track with his mention of oil viscosity then.

We will have to do a day of it soon.

Harvy

[andyb]

Got the head on and buttoned up.  Still a load of detail crap to do, but the bits that actually produce power are done.  Need to add all the little power drains yet though 

[jvb_ca]

Nice...I like the button it up part. Always my favorite part of any project..

Cheers...Jake

[fj1289]

Looks good Andy. 

Now hurry up and put it in the chassis and get it to the strip!       (Like I can talk!)

[SkyFive]

I'm almost there Andy, bottom end is completely done, all I lack is overhauling the carburetors and reworking my second cylinder head, the first one was completely worn out.




Overhauling the carburetors today



Worn out cylinder head



The exhaust seats are so worn that even the thinest shim is too large, there is no clearance. Has some cracks in the combustion chambers and the valve guides were questionable. The cam journals, saddles and caps were scored from previous incompetent assembly. This thing is garbage! Luckily I was able to locate a good and complete cylinder head. I'm going to ditch the used Ferrea intake valves and go with Yamaha valves.

[andyb]

Boy that picture of the headless motor is a familiar sight!

And hopefully one that I won't see outside of pictures for awhile!

[racerrad8]

Looks like you had the case welded where it was cracked a the rear mount, yes?

Make sure the left front motor mount has been removed, cleaned and anti-seized before putting in the bike to help eliminate vibration.

Randy - RPM

[SkyFive]

Randy,
I found a machine shop in my area that specialized in metal repair, called them and took my engine case over there. The shop looked very experienced, dark, musty, some old machines and a old man that owned it, it looked like he had been there for a hundred years. He assured me they could weld it with their "aluminum welder" for $40. so I left it with him for a couple of days. I felt confident I had found the right man for the job. The weld looked like crap, it was very messy, spatter everywhere, I spent an hour or two with a pencil grinder cleaning it up, I took half of the weld off and it still had more than enough filler to do the job. The penetration looks sufficient to hold. After cleaning up the weld I put a thin smear of JB weld over it to assure there are no leaks in case there are any pin holes. I believe it will be good.



The crack was just below the bearing numbers.

[andyb]

Whee!  Friend is over for the weekend so the motor is in the frame today!

Then I did a mockup, for a couple reasons.  First, it means that I managed to get all the CRAP off of all evarthing and give my work area a bit of a rather overdue cleaning.  Second, now I've got a pretty good idea of what all crap I need to figure out still (making some minor brackets and such, where exactly did the stupid bolt for the left rear framerail supports go, etc).  And most importantly?  The FJ turned a wheel under pushing power for the first time in what, 2 years?   Mostly it's good to see it all in one piece and be able to sit on it and go vrrrrrbrbrbrbbrbrbr with my mouth.  Actually looks like a motorbike again a bit!  Also nice is now that I can push it around easier, I managed to rearrange the garage and gain a little space, hooray!

Still a fair distance from getting it to light up, but I feel like I'm down to things that I'm comfortable with doing.  Wasted a solid 15min looking for the crankcase breather hose though, it was of course at eye level hanging from the wall.  Sigh!

[rktmanfj]

Took it for a ride today.

Experienced another brief bout with the (yet to be diagnosed) electrical issue that first showed itself at the ECSR.

Then, just when I thought I would be pushing it (at least away from the stoplight I was at), it restarted and ran fine (2up) for another 60 miles.

The bodywork comes off tomorrow...       

Randy T
Indy

[carsick]

Ah, today- adjusted my brake pedal height up to reduce toe grinding in turns. Also hit 130 (indicated) between corners, must have been close to redline with my low gearing but I didn't really have the time to look. Brakes work good though.