A bit of a cleanup (down under)

[FJools]

here is a typical example of how the gods are not aligning....................

Jools, you are having a rough trot, even your metaphors are giving you trouble. 

Noel

Weren't the planets named after gods (except Earth)? So it was right in the first place, kinda.

That's drawing a very long straw.

Noel

I'll take it though..............

[FJools]

Cant believe the last post was almost 12 months ago FFS !!

The FJ had to take a back burner while life and work got in the way, to the extent that by the time I got back to it I had forgotten what I was doing...

So here is a quick 2017 for me so far:

Christmas till Jan - UK visit to take my youngest (17) to visit her Grandma (84) before she embarks on Uni later this year as we all know what the consequences of not doing that might be.

Jan 2017  - Prepare the TZR 250 3MA race bike for the Island Classic from where it will slip out of the country to blighty for me to use at Spa during my annual visits to the Bikers Classic.

Feb 2017 - Work gets in the way of everything..........

Mar 2017 - Busy month - Prep the TZ250 for the InterFOS at Eastern creek (old Barry Sheene festival of Speed) bumped into Alf and Sparky there if memory serves me right. Contract finishes time to plan everything left to do. 2 days later get a call for work over to Adelaide for briefing. 2 trips to NZ to a) try and get Kwak GT750 working and b) in laws 70th party.

April 2017 - Actually began putting the FJ Motor back together when not working.
NOEL: Decided that Wiseco 1216cc bore cheaper than new rings.

May 2017 - Engine back in the chassis, carbs cleaned & jetted. Delkevic Exhaust fitted without any mods required...?
Carbs on engine fired up oil leaking from oil cooler fittings
May 2017 - Corrective surgery to previous procedure on left ear canal stenosis, hopefully that side will work again

[Troyskie]

I hear you Jools, similar year for me, without anywhere near as much bike fun.

I did the same for Yummy with the 1219 kit.

Been purring like a kitten.

All good with the surgery?

[ribbert]

........NOEL: Decided that Wiseco 1216cc bore cheaper than new rings........

Great to hear from you Jools. I'm with Pete, I thought you'd dropped off the edge of the planet. You've certainly had a busy year and it would be great to catch up with you in Bermagui in December if you can make it.

Did I offer some pearl on the above subject?

Noel

[FJools]

........NOEL: Decided that Wiseco 1216cc bore cheaper than new rings........

Great to hear from you Jools. I'm with Pete, I thought you'd dropped off the edge of the planet. You've certainly had a busy year and it would be great to catch up with you in Bermagui in December if you can make it.

Did I offer some pearl on the above subject?

Noel

Something about being castigated for considering re-using the original rings comes to mind LOL

[FJools]

I hadn't actually finished posting - I had to shoot off to an appointment I'd forgotten about 

So continuing.............

June - finishing up work before I head off on annual jaunt to blighty to see family, especially my new grandaughter, and do Spa. Dyno session with bike and supposedly knowledgeable operator undid all the carb work to date. Track day add Cadwell before Spa saw me reversing all these changes.....gradually.
Spa had me slowly getting it back to rideable and then the heavens opened for 2 days. So unfinished business next year.

July - Back to work and and the FJ. Oil leak at cooler unions fixed. Still leaking somewhere round the sump. Sump off cleaned, new gasket & hylomar, replaced.
Still leaking from that area - could be filter.... cover taken off and a part of the thin wall was missing, tried new O ring, no luck. Ordered spin on filter kit from Randy. Waiting.

Aug - got a call from a mate - Interfos 2018 will have 500/750 GP stroke theme so I need to get my TZ fixed. Made the silly decision to build the second bike up too  new cases and cranks, searching for parts globally emptied the bank account faster than I could fill it. Got dispensation to build new engine on dining room table....(its still there waiting for parts LOL) Filter kit arrived and fitted still leaking somewhere around that area FFS. Pulled everything off again and there is was staring me in the face - with all the stop, start of this build i had forgotten to fit a clutch pushrod oil seal. 
oil seal fitted, started - no leaks that I can see, but motor is dog rough. Balanced carbs - slightly better but doesn't like blip test. quick road test and it pulls like a train except off idle. Needs a bit of tweaking.

Sep - machining wheels for TZ750 #2 and other related stuff. In between contracts but gotta watch cash as not sure where next one is coming from. Got 3 days a week but again Christmas is coming.......Lathe motor decides to cough up so new motor ordered. Fit DRO to milling machine to make life easier.
Losing interest in FJ again..........
Changed to smaller lock up storage so had to re organise workshoto get in extra shelving and a few bikes including those I need to finish to sell off coz I'll never ride them.

So thats up to date, lathe motor arrived today so fitted that and I can get back to mountain of stuff I have to make for the TZ, but first I'm going to follow Randy's instructions on setting the air screws on the carbs of the FJ so I can at least use it for work.

[FJools]

All good with the surgery?

So far so good, but these things are notoriously slow and and I'm not one to take it easy when I should.......

[FJools]

Just posted here but is hasn't appeared..................

In a nutshell; followed Randys' instructions for setting air screws. They needed another 1 turn out after this before the blip test was good. Could probably do another 1/4 out but its much better now on test riding. Just the new Wiseco top end catching me out in low turns on side roads with engine braking. Need to sharpen up after all those 2 strokes 

Clutch is still a little draggy. I swapped over to XJR master cylinders for both front brake and clutch. Clutch has been bled 3 times but another session won't hurt. I don't want to give that 2nd gear any more of a hard time than is necessary and all the changes are pretty clunky.

Next thing is to sort out the slight leak on the LH fork seal, then service the blue spot callipers since I have the special tool and seals.

So barring a monsoon, I should be able to make the manshed day down at Bermagui - save me a spot Pete !

Jools

[oldktmdude]

   No worries mate. We'll fit you in. Monsoons won't stop us, as long as there is beer and a BBQ, it's on.
   What engine oil are you using? I only ask because the oil type and viscosity can make a big difference in gear changing. If you happen to be using a "running in"
type oil for your new motor, it has very little, if any, in the way of additives to help with smooth gear selection. I say this because I have just been through the same process using a "running in oil" and noticed gear changes improved after an oil change to my usual oil.
   I know this is controversial, but tie your clutch lever back to the bar with a cable tie overnight. Report back with the results. It has worked for me in the past for both brakes and clutch. What carb jets are you running? I'm always interested to hear what other's are using when their engines are similar to mine.
Sounds like you've almost got her done, time to put some miles on her.
   Regards, Pete.

[FJools]

Hi Pete, I'm not using a "running in" oil - just Yamaha mineral 15w50 that I bought before I had to do all the top end changes.
The clutch lever does not seem spongy, and the XJR levers are span adjustable with it set at the widest. Don't get me wrong it does'nt drag when sat at lights with the clutch in. It could well be the oil viscosity but I'll try the lever in trick.

Jetting wise I'm using s 6 Sigma Racing jet kit specific for a 92 FJ12. Outer cylinder main jets are 122.5, inner cylinders 120 as a start point (110 originals).
Pilot jets are still original I think (forget what they are!) 42.5 came with the kit but I swapped them back while I was having starting problems.
The other mod was to drill hole in slides out to 5/32 - drill supplied.
It also talks of raising the needle two notches & includes shims and nylon spacers for part needle adjustment if required but I haven't touched these yet.
It also talks of clipping a loop out of throttle valve spring if there is a lazy throttle response.
I was intending to get this set up on the dyno once I was close.

[oldktmdude]

   Your main jets sound about right but usually the richer (bigger) jets go into the inner carbs to help with the cooling. I would run 122.5's in all carbs. I think you will also be better off with 42.5 pilots and lifting the needles (oem) with the circlip in the forth groove down from the top. That's just from my experience with my motor, which is fairly similar to yours. I also have drilled out the vacuum holes in the slides but don't remember the size but it was a fair bit larger than standard. If you haven't already done the 4 degree ignition timing advance I also recommend that. Mate , you won't recognise your bike once you get it tuned right. Makes a standard 1200 feel tame.
   Regards, Pete.

[FJools]

   Your main jets sound about right but usually the richer (bigger) jets go into the inner carbs to help with the cooling. I would run 122.5's in all carbs. I think you will also be better off with 42.5 pilots and lifting the needles (oem) with the circlip in the forth groove down from the top. That's just from my experience with my motor, which is fairly similar to yours. I also have drilled out the vacuum holes in the slides but don't remember the size but it was a fair bit larger than standard. If you haven't already done the 4 degree ignition timing advance I also recommend that. Mate , you won't recognise your bike once you get it tuned right. Makes a standard 1200 feel tame.
   Regards, Pete.

Hi Pete

my bad on the main jet locations, they are as you described. I need to check on the pilots because the ones in the bag here are 42.5 but are a bit grubby and don't look like new jets so I'm wondering if they had been changed by the PO and I've just swapped like for like........... memory is a wonderful thing 
The carbs have been on and off that many times I was losing the will to live.........but I'll see how it performs on Monday when I run a few errands.
Whats involved in the 4 deg mod ? I heard mention of it on here. I could really do with some new diaphragms at some stage - I did get one to replace a holed one but pulled it off when I was having the original problems, and sealed the old one with silicone as someone on here mentioned they had done  but more of the type I got will do at some stage.

I may also recheck the shims since its bedded in a little just to be confident. Still have the auto cam chain adjuster which looked good.

[oldktmdude]

   Jools, the 4 degree advance is a simple operation, just elongate the ignition plate mounting holes (2) out to the edge of the washer shadow
lines. You must rotate the ignition plate clockwise so make sure that the holes are filed in the correct direction. A 6mm chainsaw file is ideal for this job.
If you can wait, this would be a good job to save for the Manshed weekend as would checking your shims. I have a fairly large selection of shims as well as the valve holder tool. If you decide to do the shims soon, let me know what sizes you need and we can do an exchange, I have lots between 2.70 and 2.90mm.
   Regards, Pete.

[FJools]

Cheers Pete, I think the ignition mod has manshed written all over it 

Will let you know about the shims - I did buy a kit and tool off Randy, and I have also bought shitloads of shims since, but you know what that means - probably be one or two short. Now where did I put my installed shim records..........

[FJools]

After using the bike a couple of times since the last post, I noticed the LH fork seal had gotten worse so needed urgent attention as the seepage was nearing the brake caliper.
I ordered genuine seals, dust seals and bushes from Japan which arrived earlier this week so set about doing a service. As happens the offending forks damper rod was spinning and my homemade TZ rod holding tool was too small. after much searching for something the right size to braze on the other end of the tool, I ended up machining a 27mm AF "Nut" from 35mm mild steel on the mill. Drawing it in CAD so I could get the exact amount (2.09mm) to remove from each curved edge. The first 2 cuts were easy enough being diametrically opposite then, not having any angled slips,  I had to resort to a small adjustable bevel to set up for the last cuts. Having previously drilled a 10mm hole through the centre I was able to hold it in place on the tool while I brazed it in place. 2 mins later the forks were apart - after 3 hours searching & making the tool up !!
Refilled using 10/30w semi synthetic (not sure about this though as the forks have emulators) and initial test ride seems good.

However the bike started running rough as buggery so on getting back fuel was pissing out the overflow of No 4 carb.........

Carbs removed stripped and cleaned again. Pilots checked and they are indeed 42.5 so have been swapped earlier in its life. I did notice that the ones installed were from the 6 Sigma kit and are slightly different to my eye, so I replaced them with the original Mikuni pilot jets. Carefully reassembled the float valves and the bike now starts and idles perfectly, in fact it seems better so maybe those pilots from 6 Sigma aren't really 42.5...........