Repair of the Christmas roasted FJ

[Old Rider]

My guess is there was a backfire trough the carb that set the podfilter on fire.

[FJ_Hooligan]

I doubt this is the case on Fred's FJ, but if the main ground wire has a bad connection, I've seen sparks around the shifter lever pivot shaft as ground from the engine finds a path through the shifter linkage back to the frame.

[aviationfred]

I have used this type of heat shrink/solder tube on aircraft for decades. Recently I have seen these advertised on Facebook and bought the small kit. I am giving these a try on a few of the wire repairs.

https://sharperday.com/products/necs-waterproof-solder-wire-connectors


Fred

[ZOA NOM]

Rick, remind me, you split a fuel line at the fuel filter, correct?

Correct. The filter was not a Yamaha, and the nipple was slightly large. I'll never know for certain if that was the source of the fire since it turned into a puddle, but I know it was an issue I had planned to address. I put it on a back burner, if you will, but apparently the burner was left on!

[jscgdunn]

I have used this type of heat shrink/solder tube on aircraft for decades. Recently I have seen these advertised on Facebook and bought the small kit. I am giving these a try on a few of the wire repairs.

https://sharperday.com/products/necs-waterproof-solder-wire-connectors


Fred

Yes these are awesome.....by far the best for joining wires....

[aviationfred]

An update... The carbs have been sent to RPM. I have been informed that the choke circuit has been jacked up and probably helped in causing my poor gas mileage, idle adjustment issues, and could have contributed to the fire.  

I have also located and ordered replacement parts that were damaged in the fire. All of the parts were sourced from Germany and England. Since I have removed the ABS function, I specifically searched for side panels that had the ABS absent.

While searching, I came across an oil cooler for sale that looked familiar. Upon closer look, it appears to be a RPM oil cooler with the black fittings. I grabbed it and will install it since the bike is down.

I also ordered a fire extinguisher to carry on the bike.

Fred

[Tuned forks]

I'd like to see a pic of that fire extinguisher next to an item we know the size of, like your bike, hand, tape measure, etc.  Please.

Joe

[aviationfred]

I'd like to see a pic of that fire extinguisher next to an item we know the size of, like your bike, hand, tape measure, etc.  Please.

Joe

As soon as it arrives, I will post a photo


Fred

[ZOA NOM]

I'd like to see a pic of that fire extinguisher next to an item we know the size of, like your bike, hand, tape measure, etc.  Please.

Joe

Come on, man... you got a googler?

[Tuned forks]

Looks to be about 14" or so.

Joe

[Capn Ron]

I am considering ordering one of these to keep in my top box. 

https://www.ebay.com/itm/Portable-Lightweight-Household-Car-Use-Powder-Fire-Extinguisher-for-Hotel-AH-/254025707428?skus=Color:blue&varId=553364343362


Fred

I have about six of these on the sailboat, one (and a larger one) in the rock crawler, and was carrying one on the FJ for years after a fellow rider had a huge fuel leak on the side of the road.  "When the place is on fire, no one has ever wished for fewer fire extinguishers."

[Capn Ron]

I have used this type of heat shrink/solder tube on aircraft for decades. Recently I have seen these advertised on Facebook and bought the small kit. I am giving these a try on a few of the wire repairs.

https://sharperday.com/products/necs-waterproof-solder-wire-connectors


Fred

I swear by similar connectors.  When I first bought my sailboat, every foot of every wire was corroded.  I tore it all out and replaced all of it with high-strand, tinned wire and adhesive-sealed shrink connectors from Ancor Marine.  A fellow sailor told me that it was impossible to get more than a few years out of the wire in the salt environment and he'd tried "everything".  I did that massive re-wiring job 21 years ago...not a hint of failure anywhere to this day.  When the life of me and my passengers may depend on everything going right, I'm not having to chase electrical gremlins.  My rock crawler is wired the same way...for the same reasons.

[Capn Ron]

There has been a few instances where I had fuel pour/spray directly onto my just-turned-off FJ engine. It simply boils off and flashes into vapor instantly. No spark + No Ignition.

I was there for one of them...thus my above commentary about fire extinguishers!  Yep...Not at all easy to ignite, but man if it ever did!!

[aviationfred]

Randy has found some major problems with the carbs. 

The choke circuit and mechanical are jacked up. Definitely the cause of my poor gas mileage over the last 17 months. The float levels were out and allowing too much fuel into the bowls. He also found some ham fisted maintenance from previous owner(s). I am the 4th owner. A fuel pump was connected to the carb bank, the #2,3, and 4 carbs filled with full and stopped when the floats came up. The #1 carb stayed open and had fuel pouring out of the throat. The photos are of the #1 carb showing the fuel pouring out and a bit of bad maintenance. 

Fred

[aviationfred]

The New Carbs arrived from RPM. I must say, Virgin Carbs sure do look nice.  

I did a bit of wire maintenance. The red connector from the Alternator was corroded so bad that I could not get it apart. A couple of snips and it was gone. My go to fix is Molex connectors. I still have the 4 pin connector at the steering head to replace, a little melted.

I made good progress with the mechanical stuff. The New intake boots, the almost new heat shield, carbs and UNI pods got installed. Holy smokes, getting carbs to seat into new intake boots is not fun. The New throttle cables are connected at the carbs, but hanging loose. I need to remove the original throttle cables after the before mentioned 4 pin connector gets replaced. If I get an early enough start tomorrow, I may be at a point to give it a start.  

Fred