My Initial Tear Down and Surprises lol 1992 Fj1200

[RevDeal]

So new to the forum and definitely new to this bike. I thought I would post some tear down stuff since this has definitely had work/mods done to it. I figured people here know way more than I do about what needs to happen immediately outside of the typical fj stuff.

I want to make absolutely clear... this bike is so easy to open up and work on stuff! Wow...just incredible. So here are some quick tear down pics more to come as the days go by. And questions too.


Some precursor information. The bike runs and rides great. In the few miles I have done. No issues at all!

I have never seen a gas tank liner, but I tried to get a picture of the inside. There is something funky on the tanks so unless that's how yamaha did tanks I am guessing someone redid it.

I have a ton of carb stuff that I know very little about. And I have been told these carbs have been modded, how much I don't know yet. Stay tuned...(get it?)

Some is called factory pro. The other is no name just a bunch of baggies with ss parts for the carbs.

Till tomorrow

[red]

Rev,

Somebody you know there has a borescope.  One with LED lighting and focusing ability, running on a simple USB connection (bring your own laptop), would cost around US$50 or less from Amazon.  We have ways of restoring tanks, if need be.  Let us know what you find there.  Screen captures from a borescope/laptop are easy to do.
.

[RevDeal]

More of the photos that didn't upload.
I will look into finding someone with a scope.

[Urban_Legend]

If the carbs have been modded, it is usually to make up what you lose with the pod filters. The filters change the airlow thought the carb, and most of us who have them, increase the size of the pilot jets to compensate. General rule. If it ain't borke. Don't fix it.... Borken this rule many times myself, but less about me.

Good to see the old girl get some loving from a man with a direct line to the Man. We have used his name in vain many times with our bikes.  

[Pat Conlon]

I agree with Mark, check your valves, adjust if necessary, if she runs good, leave her alone.

Re: the health of your tank; yep a borescope is good, also, get a fresh fuel filter and take your old fuel filter and cut it open. Take a peek that the filter element and look closely for rust or flakes from a poorly installed tank liner.
Kreem tank liners are known to peel off and cause all kinds of grief.....your filter will show this...

Cheers

Pat

[RevDeal]

This bike has almost 16k miles. So still a baby. Tonight was the valve clearance check, plugs, and timing cover. Here are my results.

Camshafts have a tan discoloration on the right side. Is this normal?

Valve clearances were checked on a cold engine. They were all very consistent in measurement.
EX. All checked out as loose at .178mm and very tight at .203mm
IN. All checked out as loose at .127mm and very tight at .152mm

I am pretty sure that is a good thing, but I will let you all give the thumbs up or down.



Plugs seemed to be indicating a possiblity that the air fuel mixture is a tad too rich. However, I also don't know how old these are or if with the aftermarket Dyna ignition that I might want to try a hotter plug. As of now I have had no issues when it comes to starting her. She starts first time every time. Plugs are NGK DP9EA.

I will probably do some more tomorrow, like checking torque and what not.

Does anyone know a good solution to the pealing engine coating?

[RevDeal]

More pictures

[FJ_Hooligan]

The SS bolts look like leftovers from the RPM carb bolt and o-ring kit.

Unless the motor has been beefed up, I'd back that rev limiter down to no more than 10K RPM.  Stock rev limit is 9.5K.  Unless you've got something extra to keep the valves from floating I wouldn't take it too far over 9.5K.

The brown stain on the cams is normal.

Stock plug is DPR8EA-9.  The DP9EA-9 could be a colder plug.  I think with NGK a higher number is colder.  I'd use the stock plug. EDIT: Just Googled it and bigger number is colder.

Behind the Dyna and that large round connector, look for a 2-lead red connector with red and tan(?) wires.  Unplug it and inspect for melting.

[FJ_Hooligan]

My bad.  The red connector on that year will be down below the carb heat shield. 

[aviationfred]

As David mentioned, the tan discoloration on the cams is normal. I am not sure what it is, but the discoloration is on every FJ cam that I have seen. Photo is my freshly rebuilt head done by RPM.


Fred

[RevDeal]

My bad.  The red connector on that year will be down below the carb heat shield. 

I am out of town right now, but you want me to look below the carb heat shield for melted wires?

[Pat Conlon]

Not melted wires, but a melted plug.
Read this: https://www.fjowners.com/index.php?topic=18995.0

[RevDeal]

Does this look like the problem plug?

[FJmonkey]

Yep, that looks like the plug to me.

[RevDeal]

Yep, that looks like the plug to me.

It is definitely melted! Do you have a favorite fix out of the ones listed?