Cejay
Well-known member
Well finally the Internet is back up after some clown from Telstra hooked me up to the wrong switch following my change to ADSL2. You never realise how much you miss it until you can't use it, anyways, I digress...
Couldn't sleep on Sunday morning so I ended up getting out of bed at 05:00, switch on the computer and open up the workshop manual and out to the shed to start stripping the bike for 10K service. We had planned a ride for lunch so an early start on the work was imperative but from the look of the sky and the weather forecast it was unlikely that we would leave the house.
After the treatment my bike had received at the local Yam dealers I was determined not to return there again for service work. So off with the tank, brace and heatshield and into the guts. I replaced the spark plugs first with the new Iridium set, the originals looked fine and suggested no funny business within the engine. Next step was to adjust up the slack on the Cruise control pull cable - this requires 1mm of slack but had stretched to about 2.5mm. I then had a look at the throttle return spring (ctr one) and decided some further research was in order, after spending an hour reading various threads on the FJR forums I came away still unconvinced so decided to leave it for now.
Time now to fit the new PCIII, this was a piece of cake, especially with the tank and rear mounting bracket removed, I split the plugs (not much room here) and slid the PCIII plug and socket inline, laid the earth lead over the top of the throttle bodies ready to hook up later. Now time to check the air filter, after all the dust I had ridden in and through during my earlier trip I was expecting it to be pretty bad. Getting the air filter element out proved to be major surgery, I removed the inlet tube, pulled the wiring harness out of the way (as much as I could, not much slack) and removed the four screws holding on the cover. Next I wrestled and jiggled, pushed, pulled and levered the cover part way off, this entailed pushing the 25mm thick wiring harness back behind the cover and slipping the fuel tank overflow tube underneath. There was no way the cover was coming off as the servo mechanism for the electric shift was in the way. I had checked the workshop manual for the correct procedure to remove the cover and had followed it to the letter, but, yes there always is a "but", my workshop manual is for an A model not the AS/AE. I obtained the manual surreptitiously so I can not argue or whinge and maybe this is just a bit of YamaKarma, I figured the only way to remove the cover was to remove the servo mech first. Easy enough, except, Yep excepts are just like buts only longer, to remove the servo I had to re-seat the air filter cover, bugger. After wrestling this back into place I was then able to remove the servo, a simple job but required loosening of the rear sub frame attaching bolt, that done I could once again cajole the air filter cover off and gain access to the elusive element.
Removing and examining said element, was like dancing with your sister, it was as clean as a whistle, with not a sign of the red dust that had covered the bike on my trip and was still evident on and around the engine bay. I fired up the compressor and set the regulator to 80 psi and attached the biggest air nozzle I have (10mm jet), I then proceeded to blow the bejesus out of it. Once satisfied that it had been punished enough, I replaced it and reattached the servo, reset the frame bolt, relocated the wiring harness and fuel hose, vowing next time to replace the filter with a new washable item, probably at the 20K service.
Whilst I had the servo disconnected I decided to lubricate the pivot points with some lithium spray grease as they were bone dry, I then continued to every sliding, rolling, moving and pivotting surface on the bike. Next step was to check my Motion Pro vacuum gauge for cracked hoses, surprisingly they were all still intact, so it was time to check the TBS.
I was not looking fwd to having to remove the little plugs, although 2 of them had already been removed and replaced with the hoses for the cruise control, but removing the other two would not be simple, no room for fingers only needle nose pliers. Removing the clips without dropping them was an achievement and it was when trying to break the initial grip of the plug on the tube I come to the realisation that the dealer had not checked my TBS at the first service as per the service manual (I had been charged $250.00 for an Oil and Filter change).
Before I could check the TBS I had to refit the tank, but at least all of the vac hoses were much easier to attach with the fuel tank out of the way. With the tank refitted it was time to call in the aid of SWMBO to hold up the gauge whilst I held the tank up and made the adjustments. "Ok dear you just hold this up here and I will start the engine". After 4 or five attempts to start the engine with not a hint of firing..."Did you reconnect the fuel lines?" "Of course I did do I look stupid...no don't answer that" I rechecked anyway and tried cranking again... still nothing.
After a few minutes of serious thought...."What is this wire for, over here?" "What wire, where?" "This one, the black and grey one with the hole in the end, hanging down the side of the bike!" "Bugger!" Turns out it was the earth lead for the PCIII, I had released the plug for the O2 sensor but had become sidetracked and neglected to connect the earth wire. Five minutes later and the engine was running and warmed up ready to check and adjust TBS.
The TBS was out on 1 and 2, number 3 was the reference and 4 was within 3mm. I adjusted 1 and 2 to within 3mm also and after rechecking was happy with the result. Time to remove the tank, disconnect the Motion Pro and refit the little plugs and Cruise control. When removing the plug from number 3 it had been necessary to use a bit more force than I would have liked, resulting in, yes first prize for the lady on the recliner, a split in the rubber. "Don't worry dear, you still have the 2 little rubber things you removed for the cruise control thingy don't you?" "Of course, if I could just remember where I put them!" after 20 minutes of searching and cursing I decided to jury rig it with a pin and a piece of hose from the motion pro - worked a treat - note to self buy some more rubber thingys and put them in the tool kit bag.
Replacing the rest of the parts on the bike was by comparison uneventful, and it was now time for the oil change, a simple job on this machine. I replaced the oil with a full synthetic shell oil and fitted a new filter, cleaned up the slight mess and went in to cook breakfast, it was now 12:00pm. After brunch, I dropped the oil in the diff and replaced that with a synthetic mix and was now looking forward to test riding the bike with the new PCIII fitted.
"&uck, its raining!!!" as I wheeled the bike out of the shed and into the carport, the grey skies finally decided to make good on their threat... After waiting for 30 minutes it was too much for me I had to go for a short ride around the block just to get a feel, so with the rain just trickling down, I was off and boy it felt good, the FJR had never felt this smooth, gear changes were even slicker than I could remember and the power delivery off idle was nothing short of brilliant, yep I am a happy chappy, now where is that new number plate...
Couldn't sleep on Sunday morning so I ended up getting out of bed at 05:00, switch on the computer and open up the workshop manual and out to the shed to start stripping the bike for 10K service. We had planned a ride for lunch so an early start on the work was imperative but from the look of the sky and the weather forecast it was unlikely that we would leave the house.
After the treatment my bike had received at the local Yam dealers I was determined not to return there again for service work. So off with the tank, brace and heatshield and into the guts. I replaced the spark plugs first with the new Iridium set, the originals looked fine and suggested no funny business within the engine. Next step was to adjust up the slack on the Cruise control pull cable - this requires 1mm of slack but had stretched to about 2.5mm. I then had a look at the throttle return spring (ctr one) and decided some further research was in order, after spending an hour reading various threads on the FJR forums I came away still unconvinced so decided to leave it for now.
Time now to fit the new PCIII, this was a piece of cake, especially with the tank and rear mounting bracket removed, I split the plugs (not much room here) and slid the PCIII plug and socket inline, laid the earth lead over the top of the throttle bodies ready to hook up later. Now time to check the air filter, after all the dust I had ridden in and through during my earlier trip I was expecting it to be pretty bad. Getting the air filter element out proved to be major surgery, I removed the inlet tube, pulled the wiring harness out of the way (as much as I could, not much slack) and removed the four screws holding on the cover. Next I wrestled and jiggled, pushed, pulled and levered the cover part way off, this entailed pushing the 25mm thick wiring harness back behind the cover and slipping the fuel tank overflow tube underneath. There was no way the cover was coming off as the servo mechanism for the electric shift was in the way. I had checked the workshop manual for the correct procedure to remove the cover and had followed it to the letter, but, yes there always is a "but", my workshop manual is for an A model not the AS/AE. I obtained the manual surreptitiously so I can not argue or whinge and maybe this is just a bit of YamaKarma, I figured the only way to remove the cover was to remove the servo mech first. Easy enough, except, Yep excepts are just like buts only longer, to remove the servo I had to re-seat the air filter cover, bugger. After wrestling this back into place I was then able to remove the servo, a simple job but required loosening of the rear sub frame attaching bolt, that done I could once again cajole the air filter cover off and gain access to the elusive element.
Removing and examining said element, was like dancing with your sister, it was as clean as a whistle, with not a sign of the red dust that had covered the bike on my trip and was still evident on and around the engine bay. I fired up the compressor and set the regulator to 80 psi and attached the biggest air nozzle I have (10mm jet), I then proceeded to blow the bejesus out of it. Once satisfied that it had been punished enough, I replaced it and reattached the servo, reset the frame bolt, relocated the wiring harness and fuel hose, vowing next time to replace the filter with a new washable item, probably at the 20K service.
Whilst I had the servo disconnected I decided to lubricate the pivot points with some lithium spray grease as they were bone dry, I then continued to every sliding, rolling, moving and pivotting surface on the bike. Next step was to check my Motion Pro vacuum gauge for cracked hoses, surprisingly they were all still intact, so it was time to check the TBS.
I was not looking fwd to having to remove the little plugs, although 2 of them had already been removed and replaced with the hoses for the cruise control, but removing the other two would not be simple, no room for fingers only needle nose pliers. Removing the clips without dropping them was an achievement and it was when trying to break the initial grip of the plug on the tube I come to the realisation that the dealer had not checked my TBS at the first service as per the service manual (I had been charged $250.00 for an Oil and Filter change).
Before I could check the TBS I had to refit the tank, but at least all of the vac hoses were much easier to attach with the fuel tank out of the way. With the tank refitted it was time to call in the aid of SWMBO to hold up the gauge whilst I held the tank up and made the adjustments. "Ok dear you just hold this up here and I will start the engine". After 4 or five attempts to start the engine with not a hint of firing..."Did you reconnect the fuel lines?" "Of course I did do I look stupid...no don't answer that" I rechecked anyway and tried cranking again... still nothing.
After a few minutes of serious thought...."What is this wire for, over here?" "What wire, where?" "This one, the black and grey one with the hole in the end, hanging down the side of the bike!" "Bugger!" Turns out it was the earth lead for the PCIII, I had released the plug for the O2 sensor but had become sidetracked and neglected to connect the earth wire. Five minutes later and the engine was running and warmed up ready to check and adjust TBS.
The TBS was out on 1 and 2, number 3 was the reference and 4 was within 3mm. I adjusted 1 and 2 to within 3mm also and after rechecking was happy with the result. Time to remove the tank, disconnect the Motion Pro and refit the little plugs and Cruise control. When removing the plug from number 3 it had been necessary to use a bit more force than I would have liked, resulting in, yes first prize for the lady on the recliner, a split in the rubber. "Don't worry dear, you still have the 2 little rubber things you removed for the cruise control thingy don't you?" "Of course, if I could just remember where I put them!" after 20 minutes of searching and cursing I decided to jury rig it with a pin and a piece of hose from the motion pro - worked a treat - note to self buy some more rubber thingys and put them in the tool kit bag.
Replacing the rest of the parts on the bike was by comparison uneventful, and it was now time for the oil change, a simple job on this machine. I replaced the oil with a full synthetic shell oil and fitted a new filter, cleaned up the slight mess and went in to cook breakfast, it was now 12:00pm. After brunch, I dropped the oil in the diff and replaced that with a synthetic mix and was now looking forward to test riding the bike with the new PCIII fitted.
"&uck, its raining!!!" as I wheeled the bike out of the shed and into the carport, the grey skies finally decided to make good on their threat... After waiting for 30 minutes it was too much for me I had to go for a short ride around the block just to get a feel, so with the rain just trickling down, I was off and boy it felt good, the FJR had never felt this smooth, gear changes were even slicker than I could remember and the power delivery off idle was nothing short of brilliant, yep I am a happy chappy, now where is that new number plate...
And remember to not over torque the oil drain plug as the manual's setting is way too tight and has caused stripped threads. Ouch! :angry: Before I left for WFO-6 this year I did the rear drive service on my 06 and it was so dry on the drive splines I wish I had done it when I had first got it. Used the Honda Moly 60 lube. That was fun and not difficult. 
