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[Abbynormal]

Hey guys, we may have confused you somewhere along the way with this thread. It is and has always been the front cylinder that had the oil/carbon deposit build up. One important item that happened was not posted in the previous thread. The rebuild shop for some unknown reason (in a hurry, i guess) did not change the oil in the bike after the top end. He told us to change the oil when we got it home. He did not know it was Mobile 1 in the bike. We rode 40 miles home with a new top end and Mobile 1 synthetic oil in the bike. We believe that has caused a delay in seating of the rings. The 1300 miles ridden now are with Castrol 20-50. The bike only smokes on start up. This could be either exhaust pipe due to the cross over tie in with both exhaust pipes. At this time we believe that the Mobile 1 has created the current smoking. Maybe a valve guide seal still leaks or ring problem again. Anyway, the mechanic is creditable and will honor his work with a second rebuild at his cost. We feel obligated to ride the bike per his request until proven that the problem will not go away. The vibration has decreased to a livable point. After all of the changes we have done, I doubt that the bike will ever ride as it did prior to the work. Once again, we appreciate your help and ideas.

[RedFXR2]

After all of the changes we have done, I doubt that the bike will ever ride as it did prior to the work.

Thanks for the update, but I would say that once the motor is sorted out, it certainly should ride as smoothly as before.  Again, referring to my own motor experience, I got no additional vibration after all the work/performance mods done to it.

I think I only broke in my new rings for 500 miles.  Never had any smoke on start up or anytime.  I have read Techs argue about the break-in aspects of synthetic versus conventional oils.  Take your pick.  My Tech used conventional HD oil for break-in then I went back to Amsoil.

Anyway, keep us posted and good luck.

[Abbynormal]

I have to admit, I am feeling just a bit discouraged! We have had two mechanics working on my problems, and one is a V-twin specialist with all kinds of certifications. I guess that I will just have to be patient and see how it all "shakes" out, so to speak!  You guys are great to stay in touch and offer suggestions.

Thanks

[FXR2evo99]

First of all, I am totally impressed by your articulation and manner in which you are able to relate what is happening on your FXR4.  I hope my health remains to be able to enjoy riding as well....you are an INSIPURATION!!!

We have replaced all 3 motor mounts 

I am curious if you replaced with new OEM motor mounts?

I am also curious if anyone has attempted to raise the bike off the ground and start the bike and run it through the gears.....for a minute or two....of course the next step would be to sit on the bike and see if you feel the vibration while it's off the ground....I know this sounds crazy but my bike would be held securely on my jack with me sitting on it.....of course have I done this, "no" but given the parameters that you have gone through I probably would try it....if I found it didn't "shutter" I "might" be turning my attention back to the front wheel and axle of the bike....

Could the pistons be oscillating just enough within the walls of the cylinders?


Regards,

FXR2evo99

Tim

[Abbynormal]

Yes, we used Harley motor mounts and stabilizers. Just pulled the plugs again after 50 miles (it was a nice ride and saw a small bit of the Texas Hurricane clouds pass over) the plugs appear to be clean. Some slight darkening around the base but clean tungsten. Bike still gives its personal bike fart (white puff of smoke each pipe) when starting. We have signed up for two upcoming rallies so must have the bike in top shape within 30 days. Tomorrow we take the bike by the shop just to drop off the removed plugs for inspection. I will ride it another 500 miles if he wants me to, and then take it back in for a redo on the top end if still burning oil.

Thanks so much for the nice compliment. I did not learn to ride until I was 62, and would have never made the grade ( I was scared spitless!) if not for my patient and attentive husband.

Will keep the updates coming.

[FXR2evo99]

Abby.....

So what's the latest....have you found the solution yet or what the culprit was?
I am sure you are aware of this....but just in case you are not, if you end up anywhere close to contemplating the idea of changing out your engine because of the "symptoms" you are experiencing, are you aware that HD does indeed have a EVO engine "Swap" program which you can do through your local HD dealership, it requires that you take your bike to a dealership, they pull your engine, they send it in and in a couple of weeks you get a new "rebuilt" engine back, some have said most everything typically is new just because it's easier for them....perhaps others here might be versed in what the facts are on this matter.  Once the engine arrives back at the dealership they put it back in and your off and running also included is a 1 year HD warranty on the engine......so....I believe the cost is around what $2,400.00 for the engine, then you have to pay the local dealership for the removal and installation on top of that, which allows for the 1 year warranty since of course they did all the work.  The other matter is that whatever you send in with that engine doesn't matter because all you get back is a stock "OEM" evo engine in return.....so if you have a 'hot" cam you are fond of or other goodies like screamin eagle heads, etc.. you loose them as they don't come back to you, so you either have to remove and put your stock parts back into the engine being returned or realize you will loose those items....and of course finally, if you are willing to "forego" the HD warranty for the new "EVO" engine, you could always remove your old "evo" engine, and then take it to the dealership, and then upon it's return, reinstall it yourself....this of course saves you the additional labor costs at the dealership and passes those labor charges on to however you choose to implement them yourself, via your own indy mechanic's labor or your very own labor....

So anyway.....just some ideas on a hot summer nite....I hope you get back on to the road again, perhaps you are already on the road....and all is well....

Regards,

Tim

[Abbynormal]

Yep, the FXR4 is back at the shop. Our mechanic has returned from vacation and at his cost will once again take apart the front cylinder. Maybe, just maybe, he will find the source of the engine oil in the cylinder. It will be great to once again have a normal bike to ride. Hiding from the EPA is not fun. We have fought this vibration and smoke problem for over a month. Fall is near, it is time to enjoy not repair. Stay tuned for the final chapter. May have news as early as tomorrow. We are now also enjoying our 2003 SERK. We are bike poor. My FXR4, 2003 SERK, 2003 performance enhanced (very hot) Sportster.

Elvislee, you have been SO kind to stay interested in this ongoing and lengthy saga!  I have decided to simply live with the vibration!  My husband thinks that the city will be sorry to lose their mosquito fogger!

Abbynormal

[elvislee]

Hey Abby...Well, I sure hope you get this gremlin out of your motor. I was wondering about what FXR2evo99 (Tim) said about the wheel (front)? Has everything been checked? Maybe the axle, brake rotors, balancing, or the tire itself? I don't know a lot about this stuff but just maybe something to look at if it hasn't already. I know with the smoke problem one would think somwhere in the motor, but hey; maybe just check it anyway...anyway, keep hangin in there and at least ya got some backup rides; but, I know how you love that 4 and it ain't the same...is it? Take Care and keep us posted...Best to ya...Blaine

Oh...and wouldn't ya know the kids started back school today and it's poured cats and dogs almost all day and supposedl;y for the rest of the week   

[Abbynormal]

End of story (maybe). After our mechanic removed the front cylinder, head, rockers, etc. he has determined that the bike is truly possessed. It has demons living in the engine. He found nothing wrong with anything, put the bike back together and behold, it has ceased to smoke. In all of his many years of rebuilding engines he commented that he has never had a problem such as this. I rode the bike 35 miles home with no smoke or problems. He does suspect that it is possible that the flywheel sometimes moves out of balance starts the vibrations and then corrects itself. Sounds crazy but that is the only part remaining that has not been replaced or inspected. Right now the bike is fine to ride and that is what we plan to do. Our Texas evenings and early mornings are beginning to cool a bit which make us want to hit the road. Many thanks for the support shown by all of you. Remember that "The Three Sisters" rally and ride are coming up in South Texas November 6-9th. It should be a wonderful ride at that time of year. WWW.threesistersrally.net for details We are camping at the Koyote Campgrounds on Hyw 16 South of Kerrville, Texas They have cabins as well. See you there.

[110tHunDer]

 
Strange story, but glad it seems to be OK, at least for the time-being.  Maybe take it to the next Bike Blessing in your area and hold an exorcism?

[Abbynormal]

I never realized the true meaning of "horror" until I saw parts of my fxr scattered around Plasmaman's (my husband) welding shop. Long story in short version: got the bike back for the second time from the mechanic (one top end, and another front  cylinder redo for more smoking). Rode it for about 100 miles total and suddenly it is blowing white smoke all over the county. Plasma man is fed up, says he can figure this out or die trying. He dismantles my bike, and I go off to work with my fingers crossed and wondering where I will find another fxr to ride. Lo and behold, after taking the rear cylinder down, we can see oil in the cylinder. Not only that, but it seems that (unknown to us) there may be a high lift cam there, and it took 100 miles for it to properly squish the lifters.....
Bike is now back together, and not a hint of smoke anywhere. If it starts smoking in another 100 miles we will do another top end and make appropriate adjustments.

I am ashamed for having so little faith!  Guess there is nothing more brilliant than a determined man, especially when it comes to motorcycles!  As to the vibrations that initally started this thread, we still have no idea if the two are related problems, or if they are independent. Either way, I am delighted to be back on the road for a while and just trust that things will work out one way or another.  For further updates, refer to the threat asking about removing an evo rear cylinder box. There you can read PlasmaMan's posts when he totally took over!

[elvislee]

I never realized the true meaning of "horror" until I saw parts of my fxr scattered around Plasmaman's (my husband) welding shop. Long story in short version: got the bike back for the second time from the mechanic (one top end, and another front  cylinder redo for more smoking). Rode it for about 100 miles total and suddenly it is blowing white smoke all over the county. Plasma man is fed up, says he can figure this out or die trying. He dismantles my bike, and I go off to work with my fingers crossed and wondering where I will find another fxr to ride. Lo and behold, after taking the rear cylinder down, we can see oil in the cylinder. Not only that, but it seems that (unknown to us) there may be a high lift cam there, and it took 100 miles for it to properly squish the lifters.....
Bike is now back together, and not a hint of smoke anywhere. If it starts smoking in another 100 miles we will do another top end and make appropriate adjustments.

I am ashamed for having so little faith!  Guess there is nothing more brilliant than a determined man, especially when it comes to motorcycles!  As to the vibrations that initally started this thread, we still have no idea if the two are related problems, or if they are independent. Either way, I am delighted to be back on the road for a while and just trust that things will work out one way or another.  For further updates, refer to the threat asking about removing an evo rear cylinder box. There you can read PlasmaMan's posts when he totally took over!

Hey... If the man can build such a fine grill ta cook jalapeno's on; my money is on that he'll figure this out...  

[Plasmaman]

+/- 300 miles on PlasmaMan's rear cylinder redo, and NO smoke!  Maybe, just maybe he is a genius!