Project Bike - 2006 FJR bike in a basket

[Hppants]

Not only are they clean, but they appear to be mated to the bottom end!

The puzzle put-together continues!!!!

[wheatonFJR]

Check out these intakes, how did they get so squeaky clean? And I mean, clean..... all the way to the valve seats.... I mean, really!!

Warchild's blowjob?

[raYzerman]

Very observant, Pants...... you know I've been busy....... sorta.
Wheatie, I coulda found a guy with a nice big ultrasonic cleaner, couldn't I....

[John d]

I was surprised as well at how clean the intakes were, when I replaced starter on my FJR.

[bungie4]

I was surprised as well at how clean the intakes were, when I replaced starter on my FJR.

I think that is more an indication of riding style

I wonder what the exhaust side looks like.

[John d]

^^^ I hope I never find out.

[Hppants]

If you keep an FJR long enough, or ride it enough miles, a starter problem that requires at minimum removing it from the engine is inevitable.

[philharmonic]

If you keep an FJR long enough, or ride it enough miles, a starter problem that requires at minimum removing it from the engine is inevitable.

My 03 with 75,000 miles would NEVER crank fast. Fortunately, it always started easily when cold. When HOT it would barely crank, so it was very embarrassing and even dangerous to ride in traffic, cause if you stalled it, sometimes you had to pull over to the side and wait a minute for it to cool down a little. Even getting a tank of gas was a thrill sometimes, and when it wouldn't start, it often dropped the battery voltage enough to "reset" the computer and clock. It never left me stranded, I just had to give the old gal a minute to cool off. LOL
I was so intimidated by the procedure required to change the starter, that I sold it and bought an 07 {ABS and the "dark cherry" color being the OTHER reasons I wanted a Gen. 2}

[raYzerman]

At first a PITA as you have to remove the airbox and throttle bodies to get at the starter bolts... never done it, prolly takes an hour to get where you want to go, but not complicated.

[raYzerman]

I'm such a tease.... those intakes were super clean for a reason. Here's a zoomed out view of the progress...... again look at those intakes, they seem to have a gold anodizing or something. But you can see this engine is getting ready to go, valves checked and all adjusted to exactly 70 percent of max. clearance. Another pic showing the cam sprocket timing marks when fully assembled.

[Hppants]

Sure is much easier to see those timing marks with the engine out of the bike. Mama Yammie should have stamped those on the other side of the cam gears if you ask me.

Where did you get those red “hole plugs”? That is cool and I’d like to have those before my next valve check, which is coming up.

[raYzerman]

The red plugs are for the 28mm spark plug/coolant holes, are PMI 28, but could be a bit bigger as they sit loosely in the hole, not that it matters. Flange is 29, they won't fall into the hole. One or two sizes down better for the coolant holes. I inherited these, but you could go up to PMI 31. Try your local industrial supply who make hydraulic hoses, they use them to cap hydraulic fittings, prolly give you a few fer free. While you're there, shop for o-rings.
PMI 39 fits in the intakes if you have throttle bodies off. Exhaust PMI 37. Snug fit, won't fall out.

http://www.polymermolding.com/product-p ... ed-series/
https://www.ebay.com/itm/Auto-Parts-Rou ... :rk:1:pf:0

[Festus]

Someone is going to get a gem of a bike when they buy that thing from you.

It's looking fantastic!

[Hppants]

Thanks for the advice, Ray. I know just what you are referring to re: hydraulic hose fitting protectors. We've got a hose shop in town and I'm quite certain they will fix me up. Good thinking!

[raYzerman]

Here is a pic of the engine, all ready to mount into the frame, however, I'm putting that on hold for a bit, as some frame cleanup must be done first. Valve cover on, starter installed, etc.







You should be asking or thinking something's wrong with these pictures. Now it's time to remind you your memory cells have gone bad. Better go back and read page 2. You've seen this thing before. I've been such a tease...........

[Festus]

Oh, that’s dirty Ray!

I’m starting the truck. You boys grab a sock, a bar of soap, and your passport. I’ll be around to pick y’all up shortly. Ray, don’t bother running, we will find you.

[raYzerman]

For those in the know, thanks for your support and playing along. Did any of you notice the timing, clutch and stator covers were silver and not the darker gray of Gen2? I knew right from the get-go there was no way I would reassemble the '06 motor. Too much money involved for all the parts I'd need, etc. I stumbled on this Gen3 engine from a 2014 that got hit on the right rear, at alledgedly 13,000 miles, and bought it from a salvage outfit near Rome, NY. I paid a little extra, worth it, made a day drive, it jumped into my truck one year ago. However, as I was prepping this engine, I've determined there may have been a decimal place wrong in the mileage. More later.

The old engine will be put together one day without any new parts, call it a science project. Then I may donate it to the local high school for the younger folks to edumacate themselves, unless a better idea comes along. I'll document that later, and it should be a fun project.

So about that mileage..... I've already mentioned the intakes were squeaky clean and have what appears to be a gold anodizing on them (by Yamaha), which may have started with Gen3 as I've never seen that on a previous Gen. The exhausts have a wee bit of carbon. The exterior had very little dust/dirt. The timing cover and stator cover got some minor scars, I'd rather have the new covers left in place and not retrofit the dark gray ones. It will then be more obvious it's a new engine.

Someone here (I think) mentioned a new magnetic spark plug socket (Duralast) available at AutoZone ($6.99). Get one!! Love it. Thanks to whoever that was.....



So here are the spark plugs removed from that engine...... how many miles have they gone?? I'm pretty sure the answer is not 13,000 based on all the evidence.

[wheatonFJR]

Yeah, just because of that I'm gonna leave a shit in your thread.

Don't step in it!

[Hack]

Oh, that’s dirty Ray!

I’m starting the truck. You boys grab a sock, a bar of soap, and your passport. I’ll be around to pick y’all up shortly. Ray, don’t bother running, we will find you.

Ray, you can hide out at my place until the heat's off..

[raYzerman]

Oh, that’s dirty Ray!
I’m starting the truck. You boys grab a sock, a bar of soap, and your passport. I’ll be around to pick y’all up shortly. Ray, don’t bother running, we will find you.

Ray, you can hide out at my place until the heat's off..

Now there's a real friend. A friend will help you hide a dead body. A real friend will say "I'm bringing a shovel". My landlady is having a houseful of Aussies over tomorrow, so I could use an escape. Perhaps it would be very helpful if you could post up a pic of your vicious guard dog and it will deter the posse...... and you got an in with the CBSA too, right? We'll get them held up at the border.