FJRiders.com

Front brake-light switch recall completed!

~G

I changed the engine oil and rear drive oil..

Woke in Granby, CO at dawn and started a ride in 39F. Got to Columbia, MO at dusk. It was a bit warm today in Kansas.

All day rain. It's time to do an oil change. winter oil out, summer oil in.

I rode it..for 525km..6+hrs.. a new record, with no painkillers.

CollingsBob wrote: ↑Sat Jun 24, 2023 6:03 pm I rode it..for 525km..6+hrs.. a new record, with no painkillers.

That's that good diet and exercise! Congratulations!

CollingsBob wrote: ↑Sat Jun 24, 2023 6:03 pm I rode it..for 525km..6+hrs.. a new record, with no painkillers.

Nice, Bob! That should be in the "Good News" thread as well. Glad to see you back on the bike and enjoying it.

Thankyou….


The gym 3x a week, regular massages and a good physiotherapist…I’m not completely pain free yet, but I think it’s in sight..

wheatonFJR wrote: ↑Sat Jun 24, 2023 12:09 am Woke in Granby, CO at dawn and started a ride in 39F. Got to Columbia, MO at dusk. It was a bit warm today in Kansas.

Made it the rest of the way to Travelers Rest yesterday evening. Very warm for both traveling days. I decided to use the warm weather protocol...filling up a camelbak with ice at a stop and putting the remainder in my jacket. It was awesome and kept me cool till the next stop.

Not my FJR... buddy blew the trans in his 2015, seems a chunk of gear tooth got into the middle gear hypoid gears. Chipped and broke some more teeth as it turned. It forced one part of the middle gear to be pushed sideways (to accomodate the broken bits) and broke a ring of aluminum casting off the lower engine case.... fix unknown, so he obtained a replacement engine from an '08. Spent the day yesterday retrofitting it to be a Gen3.... I learned we had to swap cams (due to sensor ring needed for Gen3 cylinder identification sensor). The rest was routine, do a valve check with the "new" cams, remove cams to reshim everything uniformly, swap in Gen3 ignition pickup and trigger wheel, swap gear position indicator switch (different connector for Gen3)..... buddy will swap in a few engine covers that are a dark gray colour on the '08 vs. brighter silver on the '15.

I had previously swapped a 2014 engine into my 2006 project bike, did not have to swap cams since the '06 does not use the newer sensor ring on the cams.

It is unknown where this chunk of gear tooth came from, can't tell until the engine is further inspected/torn down. The gears are pretty chewed up... there's more to the story somehow.... he was accelerating hard to the point of the front wheel coming off the ground... anyway, never heard of this one before..... maybe don't be doin' wheelies!

That's only the 2nd pre-2016 tranny failure I've heard of (Festus and Rob, you won the prize years ago).

People I know who have been around motocycles for decades (many decades) sometimes remind me of the "ole FJ transmission curse". This is to imply that during the "pre-FJR days", this was very common. Funny, I don't remember it that way. Sure, for people that abuse the bike, it can happen (1-2 shiftfork grenades, etc).

Ray - can you pls describe the "cam sensor"? Is that to tell the CPU where the cam is, so as not to grenade the motor if the cam jumps out of time? As an interference motor, I don't think that matters much.

This isn't a tranny failure as such, it's a middle gear failure.... if you look at the two bevelled gears (not numbered but joined by the "1"), it is these that have broken teeth. As far as buddy could see, there was no damage to the transmission gears, i.e., no broken off parts to get into the middle gear.....



Second gear failures (5 speeds) seemed quite frequent enough over the years, caused by worn dogs that would skip out of second gear under hard acceleration..... only my opinion but not getting a positive 1-2 shift is the cause, including hooligan stuff and clutchless shifting. However, an acquaintance who rode like grandma also had the issue, and I think not making positive shifts.. his second gear set was replaced.

As for the camshafts, Gen1/2 had the cylinder identification cylinder directly over #4 cam lobe and would sense the lobe going by. Starting in Gen3, there is a machined ring on the cam with a notch in it. See pic of upper (intake) cam, near the right end between lobe sets 1 and 2. This is the new location of the cylinder identification sensor in the valve cover......

I can't say it will stop anything if the valve timing jumps (a couple of teeth or more).... I'd think once that happens, engine momentum at a couple of thousand rpms is going to cause rapid destruction. AFAIK, the only thing that sensor will do is send a confirmation signal to the ECU that the engine is actually spinning over. On Gen2-up, if that sensor is unplugged, bike will not start but will spin over as long as you hold the starter button.

Ray - you'd make an excellent mechanic's instructor. You have a fine way of explaining things.

Soaked some bugs off of it. Rode just over 3,000 miles over the last 8 days. I may have to switch back to an rs3 at this rate.

Did a nice loop around the Roan Mountain area.
Good weather and good riding.
In the mountains for another day.

danh600 wrote: ↑Wed Jun 28, 2023 8:44 pm Did a nice loop around the Roan Mountain area.
Good weather and good riding.
In the mountains for another day.

Im betting Duane was close by. He loved that place.

Rode it to work yesterday. I thought I only lived 2 miles from work. For some reason, it took me 45 minutes to get home last night

Festus wrote: ↑Fri Jun 30, 2023 8:19 am Rode it to work yesterday. I thought I only lived 2 miles from work. For some reason, it took me 45 minutes to get home last night

Runnin from the cops?

wheatonFJR wrote: ↑Fri Jun 30, 2023 8:30 am

Festus wrote: ↑Fri Jun 30, 2023 8:19 am Rode it to work yesterday. I thought I only lived 2 miles from work. For some reason, it took me 45 minutes to get home last night

Runnin from the cops?

Don't judge me.

Festus wrote: ↑Fri Jun 30, 2023 9:01 am

wheatonFJR wrote: ↑Fri Jun 30, 2023 8:30 am

Festus wrote: ↑Fri Jun 30, 2023 8:19 am Rode it to work yesterday. I thought I only lived 2 miles from work. For some reason, it took me 45 minutes to get home last night

Runnin from the cops?

Don't judge me.

Do you hear a lick of judgement in that statement? lol

I'm guessing they probably caught you making some sort of awful pass and it took you 45 minutes to evade the university constable in the mid-70s model AMC Gremlin with the stick on portable Mars unit. The only judgment I might have is why it took you 45 minutes? lol