Update on My Mechanical Woes

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SacramentoMike

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As they say at the beginning of shows like "24" and "Sons of Anarchy:"

PREVIOUSLY on the FJR Forum. . . Sacramento Mike suddenly finds his bike hard to start and keep running at low rpms late on Friday (of Labor Day weekend) on the Nevada/Utah border. And a LONG way from the nearest Yamaha dealership. Hoping it's a matter of something like bad gas, spark plugs, wires, etc. (i.e., something simple), he keeps riding. All the way to Taos. While riding, by the way, the bike felt almost perfect. It was a bit rough and underpowered, but I felt fine about continuing to ride. Once I got Into Taos, though, I consulted with a couple of knowledgeable fellers (Hycle and FJRob) who advise getting it into a shop. Now. As in, don't ride it to a shop. Tow it to a shop. That's Albuquerque, about 150 miles.

I figured I'd already put about 1500 miles on since the problem began, so I pushed my luck a little farther and rode to ABQ anyway, to Bobby J's Yamaha, per local boy H.R.Zilla's recommendation. They find zero clearance on at least one valve, valve(s) probably burned, needs serious work, but they do enough to make it fairly safe to ride home ('don't take the scenic route'), shim the valves or something. Hell, I dunno. Got it to Roseville Yamaha (after a sort of scenic ride home anyway. Hell, it was pretty long either way.)

Well, I chose to have them do the work, mostly because it was the best route for peace of mind for me. Couldn't do it myself, or switch out an engine, or know who else to have do it that might have been cheaper, etc. Diagnosis: burnt exhaust valves. Badly burnt ones. Definitely made it worse by riding so far after the problem began, no doubt with one or more valves not closing completely. I did not have a valve check performed at 24K miles, but mileage now is just over 50K, so if they were out of spec, it could have developed much more recently than at the 24K point. That's what I tell myself so I don't feel so bad about blowing off the 24K mile valve check. I do not know what may have caused the valve(s) to get out of spec at this 50K plus point.

Anyway, they've had the bike for two weeks of the three weeks estimated to get it fixed. The cylinder heads are out to a machine shop getting re-milled, they'll replace the valves, the guides, the springs, the whatchacallits and all the other stuff down in there. CCT, chains, etc. too. When it's all done, I'll have pretty much a new engine that should be good for at least as long as I am, and while gruesomely expensive, much cheaper than buying another FJR, so I'm putting a happy face on it and just looking forward to getting some riding in soon. The weather around here, by the way, has been freaking GORGEOUS lately.
hissyfit.gif


By the way, with that one little exception, the ride to and from Taos was EXCELLENT. Completely avoided the dreaded desert heat and daily mountain thunderstorms I was so worried about before leaving, saw incredible and new-to-me scenery, met some cool people. Yeah, I'm still pretty glad I went. See you on the road. :)

 
Nothing like an FJR ride to put the worries on the back burner for awhile.

You'll be happy when you get your new bike back. I suppose when you do get it back, things will be tight again and will loosen up later...have a great first ride...when you do get it back. Thanks for the update.

If you Kali guys ever get to the great midwest, let me know and I can show you good roads from AR and MO east to KY, SE Ohio, over to WV and down to the Smokies. If you let me know a season ahead, I can plan my vacation around a big, long greatest roads Tour...

 
I burned one exhaust valve on my 1983 CB 1100 F in 1985. Had just had them "adjusted" 800 miles earlier. I felt the precise instant the valve burned. Rode it 500 miles home. Took it to a different shop and they said ALL valves were set too tight. Of course the original shop denied. But here's what's got me wondering... When they did the repair, the engine came out entirely. I'm sure the total bill was under $300! I suppose they simply replaced the one burned valve, maybe resurfaced that one seat but, still, just $300. So I suppose "gruesomely expensive" was over $3K? Ouch!

 
Glad to hear (despite the unfortunate cost) that your pretty blue Gen.I Feejer is gonna be healthy again. You shouldn't have to worry about ticking or CCT issues either. As long as you don't shift like Hans and get the valves checked regularly, that bike should last you a long time. Here's hoping we have a few more really nice days on the calendar when you get it back, Mike.

 
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Bummer. And peeps wonder why I always espouse getting the damned valve check done! This was a costly mistake, Mike. I feel for ya. At least it will be 'better than new' when it's all done.

Do you have any idea of how much this is all going to cost?

And where the hell are the piccies?

 
Nobody wants to see piccies of burnt valves, Scooter. And Big Sky, good guess. ;)

(Simon, I'd go for the stimulus money, but who wants to ride a solar motorcycle?)

 
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When it's all done, I'll have pretty much a new engine that should be good for at least as long as I am, and while gruesomely expensive, much cheaper than buying another FJR,
You don't want to know what I paid for my last FJR..........

:(

And of course I want piccies of the burnt valves - I want to be able to drag them out every time someone around here spouts off on 'how the FJR doesn't really need to get the valves checked'!!!!

 
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Good news...sorta SacMike. Glad the bike will be repaired and good as new, but too bad the repair $$$ are a bit on the stiff side!

Hope the weather holds out for ya! ;)

--G

 
Me, too, Mikey!

My bike is currently visiting Zac's "get-well-quick" place for FJRs....with a similar issue.

It is due for a valve adjust but I noticed a loud clacking noise from the upper right side of the engine and it started run like a dead cylinder. I got it home and it sat in the garage until I could take it (in the back of the pick-up) to Roseville last Saturday.

Best guess: A piece of carbon lodged under an exhaust valve so it was partially open when the cam came around and slapped the valve bucket and dislodged the keeper. The keeper was inside the bucket, the shim is mushroomed...all NOT GOOD! The cylinders are good and still have the cross-hatch pattern in them but the piston tops are carbon covered as are the valves. Cam measures out to spec..

Since the head has to come off for a repair....I'm going the same route as Sacramento Mike and having the head rebuilt. Like Mike, when I total all that I've added to this bike (all interchangeable with another bike but lots of work) and the rewiring for farkles, etc., I'm spending the money to have mine repaired.

It's been interesting commuting on the KLR. Way more fun to "lane-share" but not nearly the weather protection I'm used to.

 
Me, too, Mikey!

My bike is currently visiting Zac's "get-well-quick" place for FJRs....with a similar issue.

It is due for a valve adjust but I noticed a loud clacking noise from the upper right side of the engine and it started run like a dead cylinder. I got it home and it sat in the garage until I could take it (in the back of the pick-up) to Roseville last Saturday.

Best guess: A piece of carbon lodged under an exhaust valve so it was partially open when the cam came around and slapped the valve bucket and dislodged the keeper. The keeper was inside the bucket, the shim is mushroomed...all NOT GOOD! The cylinders are good and still have the cross-hatch pattern in them but the piston tops are carbon covered as are the valves. Cam measures out to spec..

Since the head has to come off for a repair....I'm going the same route as Sacramento Mike and having the head rebuilt. Like Mike, when I total all that I've added to this bike (all interchangeable with another bike but lots of work) and the rewiring for farkles, etc., I'm spending the money to have mine repaired.

It's been interesting commuting on the KLR. Way more fun to "lane-share" but not nearly the weather protection I'm used to.
Day-ummmm, Mike!!! You've been having some bad mechanical mojo on your FJR in the last year or so. I've got to get mine in for the first post tick repair valve clearance check in a couple or three thousand miles. But the more I read of this kind of thing, the more I think I may make it in sooner to see Zac soon and to pick up some Ring Free that I'll start to use regularly. I really fear that what you and Sacto-Mike have experienced is carbon deposit related. And who knows when or how that comes on?

Hope your bike is well soon.

 
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Double Damn!! I can't believe all this bad mojo. 226,000 miles on one FJR, 79,000 On the current. Only ONE CCT replacement out of all those miles (as well as the cam chain). One starter. And that is it.

Got any photos of the carbon in your engine Mikey? How many miles on that bike?

Even though I got this last FJR with 59k miles for dirt cheap there is pretty much no service history. I think it's completely possible it has never had a valve check, forks serviced, coolant, stuff like that. So even though it was a 'bargain', I am going to need to put some time and money into it. I am not riding it right now. I will say it runs strong though.

I really wish I could have seen the insides of the 226,000 mile FJR's engine. Mostly Chevron gas, and the occasional Techron or Seafoam treatment. My current FJR I pretty much started adding Ring Free EVERY fill up since 55,000 miles. I have no idea what, if any good it is doing but an awful lot of people seem to think highly of the stuff.

 
Nobody wants to see piccies of burnt valves, Scooter. And Big Sky, good guess. ;)

(Simon, I'd go for the stimulus money, but who wants to ride a solar motorcycle?)
You wouldn't have to worry about the valves though... ;) :p

Me, too, Mikey!

My bike is currently visiting Zac's "get-well-quick" place for FJRs....with a similar issue.

It is due for a valve adjust but I noticed a loud clacking noise from the upper right side of the engine and it started run like a dead cylinder. I got it home and it sat in the garage until I could take it (in the back of the pick-up) to Roseville last Saturday.

Best guess: A piece of carbon lodged under an exhaust valve so it was partially open when the cam came around and slapped the valve bucket and dislodged the keeper. The keeper was inside the bucket, the shim is mushroomed...all NOT GOOD! The cylinders are good and still have the cross-hatch pattern in them but the piston tops are carbon covered as are the valves. Cam measures out to spec..

Since the head has to come off for a repair....I'm going the same route as Sacramento Mike and having the head rebuilt. Like Mike, when I total all that I've added to this bike (all interchangeable with another bike but lots of work) and the rewiring for farkles, etc., I'm spending the money to have mine repaired.

It's been interesting commuting on the KLR. Way more fun to "lane-share" but not nearly the weather protection I'm used to.
MM2 - Sorry to hear this. You guys in NorCal seem to be hard on your superior Gen1 2005's. OUCH!
Heal those bikes up soon (and your wallets) and lets go riding! :yahoo:

 
I remain perplexed as to how a valve could get into that condition (zero clearance and burnt) after less than two valve check intervals.

I think there was either something defective, or some other extenuating circumstance at play here. I'm not discounting the need to check your valves. Clearly that is a good idea. I just don't think that you can say that it happened because they were never checked.

Cum hoc ergo propter hoc.

 
Double Damn!! I can't believe all this bad mojo. 226,000 miles on one FJR, 79,000 On the current. Only ONE CCT replacement out of all those miles (as well as the cam chain). One starter. And that is it.

Got any photos of the carbon in your engine Mikey? How many miles on that bike?

Zac has photos, I'll have him email them and I can send them to you.

95,ooo miles.

I wouldn't look past the crummy watered down gasoline we've been running for years. I guarantee that I'll be running Ring Free every other or every 4th tank fill. I don't "baby" my bike but there are those miles of freeway drone @ 4500-5000 rpms.

I can't explain it either....
 
Geez Mikes! It seems to be tough duty lately if you live near Sac, go by the name Mike and ride an FJR! Really stinks that they're both down with valve issues. Maybe it's something in the water? :rolleyes: Best of luck to you both with a speedy recovery of both bikes and wallets.

 
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