SUPER Discouraged!

[Lotsokids]

I spent all day Saturday taking care of my bike. I changed the oil, relaced the *slightly leaking* valve cover gasket, synchronized the carbs, and even re-covered the seat. I rode it to work today and it ran GREAT and very smooth. On the way home I noticed some oil smoke rising from the engine, but I assumed it was residual from where the conveniently placed oil filter dumps oil all over the exhaust collector.  BUT NO... Turns out my new $50 gasket is leaking - even through my 350 degree Celcius sealant. It started dumping oil out everywhere. I tried to carefully tighten the valve cover bolts, but then - you guessed it - I stripped one bolt. I put it all back together and now I'm too angry to make any major decisions (selling, parting out, trading). It just sucks when you do everything right, and it fails. Beautiful sunny days in the forcast, but I'll be driving the car.

Doggone it.

[Lotsokids]

I was just thinking... I remember in my car engine building days, I was told to throw away the front and rear rubber intake gaskets and just use a 1/4 thick bead of sealant only. I've done that a few times and never had any leaks. Is this an option worth trying on the old FJ?  

[racerman_27410]

did you also replace the rubber seals that go onto the valve cover bolts ?   they are notorious for hardening and leaking oil.


Kookaloo!

Frank

[rktmanfj]

Is it stripped or twisted off?

Either way, I wouldn't even briefly consider parting out an FJ because of it.  Just repair the thread or remove the broken bolt, and do as Frank suggested and replace the cover bolt rubbers (2GH-1111G-00-00 RUBBER, MOUNT 1).

Then replace the gasket WITHOUT sealant, using a torque wrench on the cover bolts.  They have a pretty low torque spec... you are far from the first to break one off.

IMO, a full set of cover bolt rubbers and cover gasket should come as a package.  If you need one, you're sure to need the other.

Cheer up, it could be LOT worse!        

Randy T
Indy

[SkyFive]

Then replace the gasket WITHOUT sealant

^^^ This! ^^^

I use to put sealant on everything many years ago (1988) until a good mechanic (the best I've ever seen) asked me why I did that and of course I answered because I want a good seal. Then he pointed out that this is what a gasket is for and then he showed me how to clean a gasket surface  perfectly clean with a razor blade. This was one of the best lessons I've learned over the years.

[Travis398]

Take a moment to vent, parting the bike is the last thing that should be done.

I have to agree with the other guys no sealant, especially on a new gasket.

when I changed my gasket I changed the rubbers on the bolts also.

I thought the extra $20 might save me from doing it twice.

also, once the shoulder of the bolt bottoms out..going tighter will do nothing for your leak.

At the risk of getting flamed I will add,  I did use a couple dabs of grease on the gasket to hold it in place while I put the cover on. 

No leaks.................

[Harvy]

also, once the shoulder of the bolt bottoms out..going tighter will do nothing for your leak.

At the risk of getting flamed I will add,  I did use a couple dabs of grease on the gasket to hold it in place while I put the cover on. 

No leaks.................

Yep.......the bolts hold the cover on.....the grommets hold the oil in.

The gasket is a bugger if its been all scrunched up in its packaging for a while. I have used double-sided printers tape in the past just to hold it in place...... tired grease too but it wouldn't sit still.

Harvy

[Flying Scotsman]

Take a moment to vent, parting the bike is the last thing that should be done.

I have to agree with the other guys no sealant, especially on a new gasket.

when I changed my gasket I changed the rubbers on the bolts also.

I thought the extra $20 might save me from doing it twice.

also, once the shoulder of the bolt bottoms out..going tighter will do nothing for your leak.

At the risk of getting flamed I will add,  I did use a couple dabs of grease on the gasket to hold it in place while I put the cover on. 

No leaks...............



\]]..

Grease is a good thing you can use it on rubber and fiber/paper type gaskets.

Holds gasket in place and can help the seal if need be.

[paulfj03]

Lotsokids,

I did the same thing this past spring! I was just replacing a couple of the rubber grommets for the valve cover bolts as they were seeping oil. I broke off the shoulder bolt! "NO WAY!"  I also had the setting on the torque wrench correct! WTF! now the whole valve cover has to come off and get the bolt out....ya I had to walk away for a good while....then I got another few bolts and a gasket(thx randy) and it was fairly easy getting the broken bolt out . SO! I try again....didn't I snap another bolt off in the same dam place again! NO WAY! yup. Unbelievably frustrating!.....to make a long story short, i did get it back together without leaks ...hahaha I can laugh about it now and i had a good summer riding and a good fall so far......so don't part out or sell that nice clean looking FJ!  btw I like those colours...

+1 on just using the gasket without sealant...i put a tiny bead (like the others have mentioned) just to hold the gasket in place while placing the cover on. The manual recommended putting a bit around the 2 recesses (right side) of the gasket as well, so i have been doing that with no leaks (so far).
Cleanliness of both surfaces,imo, makes the biggest difference.

So just imagine having to do that twice

Good Times!!!!

[the fan]

I usually use a small amount of Gasgacinch to hold troublesome gaskets in place.

http://www.gasgacinch.com/gasgacinch_002.htm
In most cases I try to place the gaskets dry but the Gasgacinch works great when needed. I only use sealant when the FSM calls for it and then very sparingly.

[andyb]

Because they're shoulder bolts, they're actually pretty easy to pull from the cam cap.   Pop the cover off, pull the cap, carefully back the broken bit out,  reassemble.  On the gasket you should just have a couple drops of sealant, just at the corners of the halfmoon things to hold them in place while you work.  Replace the rubber bits on the cover screws, and you're done.  Setbacks suck, but that's a relatively quick one to fix, so carry on!

[Lotsokids]

Thanks, all. 
I took a breather, and all should be fine. But hey, I didn't wreck, or trash the transmission (which I have experience in), so it could always be worse. I just get frustrated with trying to save money by buying old crap that I have to CONSTANTLY keep working on, then miss time spent with my wife and 6 kids. I'd probably be better off just dumping about $10,000 into a bike that I don't have to tinker with. You can't put a price on time with family.

Good advice about the seals. I emailed a parts request today to the Yamaha shop. Another factor is that I live in Hungary where they DO NOT speak English. So you can imagine the challenge ordering parts.

At this point, I still do not know if I broke the bolt off or just stripped it. If I stripped the head, that creates another challenge. I'll know in a few days.

Anyone else HATE driving a car on nice sunny days?   

[rktmanfj]

Another factor is that I live in Hungary where they DO NOT speak English. So you can imagine the challenge ordering parts.

Scroll up.

I supplied the p/n for the cover bolt seals up there...

You can look up anything on the fische yourself here: http://tinyurl.com/a84pt

That should help with the language barrier.

Randy T
Indy

[Lotsokids]

Scroll up.

I supplied the p/n for the cover bolt seals up there...

You can look up anything on the fische yourself here: http://tinyurl.com/a84pt

That should help with the language barrier.

Randy T
Indy

Yes, I got it. Thanks. I was just speaking in general terms. Every time I go in there, I have to point at a part on a bike in the showroom or they bring up the drawings and I point at items on his screen. It's not easy. Especially on his end when he tries to tell me it will not come in for 4 days or something like that.

[Arnie]

Every time I go in there, I have to point at a part on a bike in the showroom or they bring up the drawings and I point at items on his screen. It's not easy. Especially on his end when he tries to tell me it will not come in for 4 days or something like that.

4 days!! ? You're frustrated at having to wait 4 days   That would be considered instant service in most dealerships in Australia, and many in  the US even for brand new bikes.
Your FJ is over 22 years old and the model run ended in 1993 - 17 years ago.  Be glad that parts are available at all.  Patience is your friend.

Cheers,
Arnie