Engine Didn't Grenade/Something Happened/And Final Report

[Intech]

Did some work this weekend. Pulled the fuel rail off and pressurized with injector cleaner. No leaks. Rigged a power supply open each of them to clean and check spray patterns. All worked fine with no noticeable issues. Moving on with reassembly.

 

[08FJR4ME]

Will you be doing a compresion test on the cylinders?

Dave

 

[Intech]

Yes

 

[08FJR4ME]

Just checking in on progress.

And the prognosys is: _ _ _ _ _ _ _ _ _ __ _?

Dave

 

[Uncle Hud]

08FJR4ME posted: Just checking in on progress. And the prognosys is: _ _ _ _ _ _ _ _ _ __ _?

The engine did not grenade, and something happened. Hopefully, that is NOT the Final Report.

+++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++

Should be a new rule: if a thread lies fallow for two weeks or longer, it's fair game for mischief.

 

[Fred W]

Glad you revised that post. Gillian was always just a whiney biotch on the show. I wouldnt want her as a pillion percher even if she looked better than she does.

 

[Intech]

I am still working on getting the engine back in the bike. Did some reassembly and torqueing last night. Unless something else comes up, I should have the engine back in the bike this weekend.

 

[Bounce]

So, engine back in the bike. What was the diagnosis/fix that went into it before that?

 

[Uncle Hud]

Negatory, Nuevo Hampshiro ...

 

[Intech]

Bounce - So far nothing out of the ordinary. Keep in mind that I have only rotated the engine via the crank without the plugs installed. Given all the other symptoms I don't suspect any compression issues. It rotated freely with no abnormal noise or resistance. That was when I found the gas in #2 cylinder. I think the root cause will be determined by finding out why all that fuel was there. Need to closely examine the spark plug wires too. Plug looks good. At this point I wish we were not in such haste to blame the mechanical parts of the engine and pull it off the bike. I enjoy working on it, though. I will try to keep this up to date as much as possible.

 

[dunhamg]

If I recall, he had climbed a curb and bent (creased) at least 2 header pipes, causing the engine to run much hotter than normal. This went on for quite some time.p.s. when he bought that bike from me, it was running like a top, as good as new, and still had a few months of YES warranty left. I only sold it to upgrade to a Gen II 2008.

I had forgotten about the crunched header pipes. It is true that when Patriot got that bike it was in excellent shape. He did not take care of it and did not look after it, he just rode it and did what he knew how to do.

Which actually makes Intech's situation all the more confusing. Other than a CCT does anyone ever remember an FJR engine "grenading"? Even under the worst of situations there are usually warning signs over a period of time.

I am very curious as to what Intech and company find inside that motor. While I hope they do find a cause I still think it would be cheaper and easier to find another used FJR and start over.

I did have a FJR "grenade". A rod let go on it at 137K miles. I will admit they may have been fairly strenuous miles

Grady

 

[Intech]

Did some more work today. Everything buttoned up on the engine. Performed a valve clearance check prior to doing a cyclinder leak down check. I have done all three clearance checks on this bike and never had to make an adjustment the last check was September of last year. All the intakes were .152 to .155 exactly the same as the first check. All the exhaust were ideal at .229 last year. Today I found three clearances at .290, two at .300 and the remaining at .250. Something definitely happened to this engine to cause them to shift that much.

The question is what? Any suggestions would be helpful.

 

[FJRay]

It's odd that the clearance would grow. Usually if anything they get tighter. If a leak down showed exhaust leakage I would suspect a lot of carbon build up and a hot load of ring free or seafoam should help. Sometimes running premium can cause some carbon because it burns slower than the FJR is designed for. Just guessing.

 

[Fred W]

Yeah, if you can get ahold of a Boroscope it would be good to see how carboned up the combustion chambers are.

We have to remember that one cylinder was full of fuel at one time too. This is a pretty crazy set of symptoms

 

[TownsendsFJR1300]

Just an FYI, a "shock dose" for Ring Free is 2 OZ / 1 Gallon of fuel...

As the larger clearances are ALL on the exhaust side, it'd have to be carbon build up.

What were the leak-down #'s?

 

[RossKean]

I assume that the leakdown would be awful if there was that much carbon buildup preventing the valves from closing all the way. A clearance change of 0.071 is huge.

(I guess we are hoping that any foreign material on the valve seats is carbon rather than metal fragments!! Would hate to find out that the original diagnosis was correct!)

I don't suppose there is ANY chance that the camshaft cap bolts backed off at some point...?

 

[TownsendsFJR1300]

I assume that the leakdown would be awful if there was that much carbon buildup preventing the valves from closing all the way. A clearance change of 0.071 is huge.

A bent valve, not closing fully would open up those clearances...

That's why I asked about leak down #'s..

 

[Fred W]

I assume that the leakdown would be awful if there was that much carbon buildup preventing the valves from closing all the way. A clearance change of 0.071 is huge.

A bent valve, not closing fully would open up those clearances...That's why I asked about leak down #'s..

Dont think he could have bent all of the exhaust valves and have the intakes unchanged. Im banking on some serious carbon build up. Maybe Bobs brother was running some Mexican gas through it or something? Still doesnt explain the acute symptoms, Fuel in one cylinder, or metal shavings in oil.

 

[Intech]

I haven't done the leak down test yet as I still have another exhaust to adjust into tolerance. It wasn't just the exhaust that opened up either. All of the intakes went from the lower end of tolerance to the high end with 1-2 out of tolerance at .270.

 

[TownsendsFJR1300]

The leak down test will / should show any issues(especially carbon build up with leakage audible).

If the header and TB's are off now, leave them off until the test is done. Just easier to hear leakage.

As the injector for that cylinder was not leaking (later), is it all possible the fluid was coolant

(blown head gasket)?