Topic: Abby's Engine (Read 20447 times)

Abbynormal · « **on:** November 14, 2009, 08:59:15 PM »

Enough is enough, my evo has vibrated for a year and we finally ran out of ideas on how to solve the problem. Our last ditch effort has resulted in removing the engine. Sending jugs to be bored, new pistons, sending case, crank and pistons to Truitt and Osborn to balance the crank and install new bearings. While we have it apart a new and better cam may be in order. Our mechanic mentioned Andrews EV23. Comments about the cam anyone? Hopefully the bike will be back together within 4 to 5 weeks. Texas still has great riding this time of year. Hope all of this effort and money solve the problem once and for all.

Abby and Plasmaman

Hoist! · « **Reply #1 on:** November 15, 2009, 03:22:06 PM »

Damn Leanne, you aren't having much luck with that motor. Why not check out HD's rebuilding program, and have it factory rebuilt. They build it back to stock, but it's prolly the best rebuild you can get, and it's fairly reasonable in price. Something to consider!

HD Engine Remanufacturing

HD Engine Remanufacturing Options and Pricing

Hoist!

lucille · « **Reply #2 on:** November 15, 2009, 04:58:08 PM »

Hi Leanne,

With your FXRs gearing, the EV27 would be a nice choice also...
Not sure 'what's up' with the vibration problem....on FXR bikes the vibes usually creep up on you, you wonder if it's your imagination at first.
Generally cured with a change-out of the stabilizers, and swingarm rubbers/spacers, followed by a powertrain alignment.
Besides wheel balance, have you checked for an 'out of round' tire/wheel?.......do this with a dial indicator.
Good luck......

Plasmaman · « **Reply #3 on:** November 15, 2009, 08:25:56 PM »

Thanks Hoist and Lucille for your input. We elected to go with our local mechanic and Plasmaman will do a lot of the work cause it's fun and also save a little money. Over the past few months we received several suggestions to try and try we did with no luck. This engine kept changing, sometimes smoother and sometimes put your feet to sleep. It was for certain in the engine and not the frame. We have new motor mounts, new tires, check runout on alternator, check clutch, did a valve job and new rings, etc so with 33K on the engine Abby wanted a rebuild and add the better cam. She thinks she can keep up with my modified sportster but it ain't gonna happen. Anyway, cylinders back on Tuesday and ship the crank and pistons to Wichita KS for balance. Then we take all of the parts we can find and put it back together. Thanks for trying to help and ride safe.

Plasmaman

Black Diamond · « **Reply #4 on:** November 15, 2009, 08:31:14 PM »

Put a Wood W6 cam in her. She'll keep up just fine!

JW

jfh · « **Reply #5 on:** November 20, 2009, 08:35:55 PM »

Quote from: Hoist! on November 15, 2009, 03:22:06 PM

Damn Leanne, you aren't having much luck with that motor. Why not check out HD's rebuilding program, and have it factory rebuilt. They build it back to stock, but it's prolly the best rebuild you can get, and it's fairly reasonable in price. Something to consider!

HD Engine Remanufacturing

HD Engine Remanufacturing Options and Pricing

Hoist!

Hoist,

I can't believe you are recommending a MoCo rebuild for an 80" Evo! You know there are far better options out there that will still offer stock-like reliability and durability.

Hoist! · « **Reply #6 on:** November 21, 2009, 01:11:48 AM »

Quote from: hdfr120 on November 20, 2009, 08:35:55 PM

Hoist,

I can't believe you are recommending a MoCo rebuild for an 80" Evo! You know there are far better options out there that will still offer stock-like reliability and durability.

I thought she'd be gun shy of home-builts after all the grief she went thru with this motor is all. I'd go the building one route myself. But the stock Evo rebuild program isn't a bad deal if you like stock performance.

Hoist!

jfh · « **Reply #7 on:** November 21, 2009, 03:03:14 PM »

Quote from: Hoist! on November 21, 2009, 01:11:48 AM

I thought she'd be gun shy of home-builts after all the grief she went thru with this motor is all. I'd go the building one route myself. But the stock Evo rebuild program isn't a bad deal if you like stock performance.

Hoist!

If they would allow you to do the labor yourself, the remanufacture program wouldn't be a bad deal. They even offer a new All Black Option (PN:16007-99A) for $1756 at Chicago HD. Just gotta find a stealer willing to do an exchange without the labor.

djkak · « **Reply #8 on:** November 21, 2009, 10:32:43 PM »

Quote from: hdfr120 on November 20, 2009, 08:35:55 PM

Hoist,

I can't believe you are recommending a MoCo rebuild for an 80" Evo! You know there are far better options out there that will still offer stock-like reliability and durability.

Quote from: hdfr120 on November 21, 2009, 03:03:14 PM

If they would allow you to do the labor yourself, the remanufacture program wouldn't be a bad deal. They even offer a new All Black Option (PN:16007-99A) for $1756 at Chicago HD. Just gotta find a stealer willing to do an exchange without the labor.

Consider that along with the reconditioning, damaged/unusable cores are replaced at no additional charge; cases, heads and cylinders get a fresh powdercoat; chrome pieces are replaced with new; comes with a 1 year, nationwide warranty. The cost/value is extremely strong with the Factory recon engine.

It may be possible to swap one without the Dealer R&R; although you would probably lose the warranty.

Abbynormal · « **Reply #9 on:** November 22, 2009, 02:58:19 PM »

Well guys, it's a done deal. Jugs now bored 20k over with new pistons, rings, pins. Engine lower unit on the way to Wichita KS for crank balance, new bearings, etc. Hotter cam ordered along with gasket kits as required. We had already done the heads and will just do some polishing. Will let you know total cost involved when this project is completed. Keep in mind that Mike and our mechanic are doing disassembly and reassembly of the bike here at home. We will pay the bike shop to assemble the engine to the point it is ready to install. We just decided that we wanted to retain the original engine and hoped that the cost would be about the same as buying a Harley rebuild.

djkak · « **Reply #10 on:** November 22, 2009, 07:07:53 PM »

Quote from: Abbynormal on November 22, 2009, 02:58:19 PM

......We just decided that we wanted to retain the original engine and hoped that the cost would be about the same as buying a Harley rebuild.

It read like you had already committed to a course of action; I’m just trying to keep my keyboarding skills current.

With H-D’s remanufactured engines, you keep your original engine number, even if the crankcase is replaced; unlike when purchasing a new “off the shelf” engine.

Good luck with your project.

Plasmaman · « **Reply #11 on:** December 10, 2009, 02:41:23 PM »

Salt in the wound. Word from Kansas was that the crankshaft was not bad but one of the rods did need attention. Most likely the lower end was not causing the vibration but we went ahead and had it totally rebuilt and balanced. The container with engine arrived today. I had built an angle iron frame crate with plywood sides to protect the engine in shipment. The engine was bolted to an engine stand and the stand bolted to the floor of the crate. All four sides and the top clearly marked "THIS END UP". Well, as Abby's bad luck would have it, UPS dropped the crate from considerable height and hit on the crank end. A large dent is in the top of the block and another damaged the primary face. One piston crushed. The engine hit hard enough to rip the plywood floor with engine attached loose and was lying on its side in the crate. So, now we fight with UPS and send the engine back to Kansas to be balanced and damage repaired. This really sucks and as you would expect, Abbynormal is livid.

miker · « **Reply #12 on:** December 10, 2009, 02:52:41 PM »

YGBFKM!

chite! Sorry to hear of the troubles....

Fired00d · « **Reply #13 on:** December 10, 2009, 03:07:26 PM »

Quote from: Plasmaman on December 10, 2009, 02:41:23 PM

Salt in the wound. Word from Kansas was that the crankshaft was not bad but one of the rods did need attention. Most likely the lower end was not causing the vibration but we went ahead and had it totally rebuilt and balanced. The container with engine arrived today. I had built an angle iron frame crate with plywood sides to protect the engine in shipment. The engine was bolted to an engine stand and the stand bolted to the floor of the crate. All four sides and the top clearly marked "THIS END UP". Well, as Abby's bad luck would have it, UPS dropped the crate from considerable height and hit on the crank end. A large dent is in the top of the block and another damaged the primary face. One piston crushed. The engine hit hard enough to rip the plywood floor with engine attached loose and was lying on its side in the crate. So, now we fight with UPS and send the engine back to Kansas to be balanced and damage repaired. This really sucks and as you would expect, Abbynormal is livid.

Wow!!! That sucks!!!!

Ride Safe,
Fired00d

Hoist! · « **Reply #14 on:** December 10, 2009, 03:44:01 PM »

Holy crap! That's terrible! So sorry to read this! Not what we wanted to hear of course! I hope you don't get screwed around by them, and can get her motor back from them in a timely fashion. And of course, at no additional cost to you. Good luck!

Hoist!

Twolanerider · « **Reply #15 on:** December 10, 2009, 05:33:01 PM »

Please say that when the shop in Kansas sent it back to you they did properly insure the parcel. If they did it's too obvious damage for UPS to try to avoid. They're not the fastest to pay claims. But they do pay them.

sadunbar · « **Reply #16 on:** December 10, 2009, 05:52:06 PM »

I am sure you have taken lots of pictures....if not, you should. My experience is UPS pays claims promptly when the package is lost - but is more difficult regarding damage. They will make a "judgement" of whether or not the packaging was proper for the shipment. But, if they determine the packaging was adequate - they will pay the insured amount. The process can be quite lengthy - especially around the holidays - but they'll pay.

Plasmaman · « **Reply #17 on:** December 10, 2009, 07:08:33 PM »

Thank goodness we were dealing with a good reputable company in Kansas. Truett & Osborn have indicated that since they shipped back to us, they are willing to do repairs at no cost to us. I assume that since it was sent on their end they were responsible for the insurance. When I shipped to them I insured for $2000. We are waiting to hear from UPS on what to do. Many pictures were taken from the time box was opened to detailing the damage. I have dealt with UPS on another small claim and they were slow and difficult to deal with. Hope this is a better experience. Thanks for your concern. Will post results with UPS when we hear.

Plasmaman

Twolanerider · « **Reply #18 on:** December 10, 2009, 08:36:54 PM »

Quote from: Plasmaman on December 10, 2009, 07:08:33 PM

Thank goodness we were dealing with a good reputable company in Kansas. Truett & Osborn have indicated that since they shipped back to us, they are willing to do repairs at no cost to us. I assume that since it was sent on their end they were responsible for the insurance. When I shipped to them I insured for $2000. We are waiting to hear from UPS on what to do. Many pictures were taken from the time box was opened to detailing the damage. I have dealt with UPS on another small claim and they were slow and difficult to deal with. Hope this is a better experience. Thanks for your concern. Will post results with UPS when we hear.

Plasmaman

As frustrating as it will be for you there's little for you to do. UPS won't (at least initially) do much at your request. You weren't the shipper this time so you weren't their paying customer. The shipper will need to initiate the claim. UPS will then want to inspect the damage. They'll do their paperwork and then pay the claim amount to the shipper.

Don't send it back to the shop yet. And don't mess with the crate any more than absolutely necessary. If UPS can't see the damage and the transit container you're giving them leverage to debate the claim.

Plasmaman · « **Reply #19 on:** December 16, 2009, 02:12:45 PM »

We saw this coming. Shipped the engine block and pistons back to Kansas for repair of damage done by UPS. Well, guess what, UPS opened my crate in Ft Worth and has determined that no damage ever occurred. I had no idea that Leslie at UPS was also an engine specialist. I guess the big dent in the top of the block will not really need to be sealed or the one in the primary repaired. Heck, who cares if it won't hold oil or compression. I am certain that just by looking, UPS can determine that landing on the crankshaft end could not possibly affect balance. The big dent in the piston surely won't hurt anything either. So guys, if you need any technical assistance with your bikes just call UPS and they will assist you.

I am removed from this fight because Kansas shipped to me and they have to deal with the jerks. Fortunately we have numerous pictures of the damage and the condition of the crate upon arrival in Mineral Wells. Truett and Osborne will make the repairs regardless of UPS. They are good folks to deal with. Hey, FED X how about some business.

Plasmaman

sadunbar · « **Reply #20 on:** December 16, 2009, 02:22:16 PM »

Quote from: Plasmaman on December 16, 2009, 02:12:45 PM

We saw this coming. Shipped the engine block and pistons back to Kansas for repair of damage done by UPS. Well, guess what, UPS opened my crate in Ft Worth and has determined that no damage ever occurred. I had no idea that Leslie at UPS was also an engine specialist. I guess the big dent in the top of the block will not really need to be sealed or the one in the primary repaired. Heck, who cares if it won't hold oil or compression. I am certain that just by looking, UPS can determine that landing on the crankshaft end could not possibly affect balance. The big dent in the piston surely won't hurt anything either. So guys, if you need any technical assistance with your bikes just call UPS and they will assist you.

I am removed from this fight because Kansas shipped to me and they have to deal with the jerks. Fortunately we have numerous pictures of the damage and the condition of the crate upon arrival in Mineral Wells. Truett and Osborne will make the repairs regardless of UPS. They are good folks to deal with. Hey, FED X how about some business.

Plasmaman

The only thing they understand....

mjb765 · « **Reply #21 on:** December 16, 2009, 02:51:06 PM »

At least the company that did the work is doing the right thing for you.

fxr4mikey · « **Reply #22 on:** December 28, 2009, 07:44:48 PM »

Quote from: Black Diamond on November 15, 2009, 08:31:14 PM

Put a Wood W6 cam in her. She'll keep up just fine!

JW

if she does, she won't be keeping up with no modified sporty, she'll be LEADING !!!!!!!!!!!

fxr4mikey · « **Reply #23 on:** December 28, 2009, 07:50:25 PM »

Quote from: Plasmaman on December 10, 2009, 02:41:23 PM

Salt in the wound. Word from Kansas was that the crankshaft was not bad but one of the rods did need attention. Most likely the lower end was not causing the vibration but we went ahead and had it totally rebuilt and balanced. The container with engine arrived today. I had built an angle iron frame crate with plywood sides to protect the engine in shipment. The engine was bolted to an engine stand and the stand bolted to the floor of the crate. All four sides and the top clearly marked "THIS END UP". Well, as Abby's bad luck would have it, UPS dropped the crate from considerable height and hit on the crank end. A large dent is in the top of the block and another damaged the primary face. One piston crushed. The engine hit hard enough to rip the plywood floor with engine attached loose and was lying on its side in the crate. So, now we fight with UPS and send the engine back to Kansas to be balanced and damage repaired. This really sucks and as you would expect, Abbynormal is livid.

wow, just unreal !!

I've been reading your's and Abby's post for a year or so. I never had anything to add that I thought could help you.
I still don't, but I sure do pass you Good Thoughts that things will improve with ya'll and this FXR4.
Best of Things to you !!!!!!!!!!1

fxr4mikey · « **Reply #24 on:** December 28, 2009, 07:55:00 PM »

I was Happy to read that the folks out west are going to do the repairs ... and ship back FedX no DOUBT !!

Let us know how it goes .... GOOD LUCK !!!!

Plasmaman · « **Reply #25 on:** January 06, 2010, 10:22:28 PM »

The good news is that we now have the engine back home and will ready to install by tomorrow night. Truett and Osborn did a marvelous job repairing the damage UPS did to the block. You cannot detect the damaged areas from the rest of the block and primary case. I can't say enough good things about them. UPS is another matter. My last conversation with Truett and Osborn indicated that UPS refuses to pay even though they had the crate insured. Folks, they dropped this engine from enough height that it sheared the self tapping screws which held the crate bottom and engine stand secure. Had I known that trained gorillas were going to be running the fork lifts, etc I would have used more screws. This is my second go around with UPS claims and they are both bad. Why pay for the insurance if the first thing they say is "It's not our problem, you should have packed it better". I think at least 60 percent of the folks making claims will just give up and say screw it, it is not worth the hassle so they get out of paying. Our UPS delivery man is a great guy and I am not coming down on the hardworking guys and gals doing their jobs but management sucks. Will give you a report after the bike is completed. The extreme cold is about to hit Texas and my shop is not insulated. May be a few days before we get to ride.

Be safe,
Plasmaman

faceracer · « **Reply #26 on:** January 07, 2010, 10:31:12 AM »

Wow sorry to hear what happened! UPS is notorious for throwing your chit around. I purchased a $5k computer from dell in 97 and the local UPS guy dropped it off the truck, then dropped the monitor and computer off his dolly in my driveway which was a steep hill and they rolled down the driveway! I stood and watched the whole thing in horror! I refused delivery and made them send it back to dell! Did not even want to see what the inside looked like!

What can Brown due to you? Stain my shorts?

Artlee · « **Reply #27 on:** January 08, 2010, 09:05:34 AM »

I had job with UPS back in the early 80s during the Christmas rush. I used to be one of the guys unloading trucks. We used to have a competition amongst ourselves to see who could throw their packages the furthest ( from inside the trucks we were unloading ) and see if the boxes would land on the conveyor belt. Got pretty good at that. Took a few throws to get the right range.The managers didn't care, it was all about unloading trucks as quick as possible. Hopefully it is not like that now. But ever since that job, I have been very very careful how I pack things going via UPS. I have had good luck with FedEx, a bit more expensive, but up here FedEx has done a great job for me. Still, I don't know what goes on in the FedEx warehouse.

Hope your luck has turned for the better.

sadunbar · « **Reply #28 on:** January 08, 2010, 09:53:52 AM »

Quote from: Artlee on January 08, 2010, 09:05:34 AM

I had job with UPS back in the early 80s during the Christmas rush. I used to be one of the guys unloading trucks. We used to have a competition amongst ourselves to see who could throw their packages the furthest ( from inside the trucks we were unloading ) and see if the boxes would land on the conveyor belt. Got pretty good at that. Took a few throws to get the right range.The managers didn't care, it was all about unloading trucks as quick as possible. Hopefully it is not like that now. But ever since that job, I have been very very careful how I pack things going via UPS. I have had good luck with FedEx, a bit more expensive, but up here FedEx has done a great job for me. Still, I don't know what goes on in the FedEx warehouse.

Hope your luck has turned for the better.

yeah...let's hope.. I assume your performance on this job wasn't one of your prouder moments..

Artlee · « **Reply #29 on:** January 08, 2010, 11:17:26 AM »

Nope not one of my prouder memories. However, when the manager is chewing you for being too slow, you pick up the pace or pick for home. The SOP was to stand in the back of the truck and throw ONLY 6 feet to the belt - that was how it was done. Just sayin'

Plasmaman · « **Reply #30 on:** January 11, 2010, 07:24:41 PM »

Yea, Abby's engine is now back in the bike and purring. Only 26 miles so far but sounds and handles ok. We will need to jet the carb since we changed the cam, bored 20 over and changed pistons. Seems to need more fuel to insure we don't run it lean while in the 500 mile break in period. Did we spend $2000 to fix the vibration problem for nothing?

?? Don't know yet but will learn more when we log some miles. Temps forecast to be about 54 deg tomorrow so will put about 100 more miles on the engine. Nothing more to report about UPS except I still think management wins the Chithead award hands down. Abbynormal is smiling ear to ear to be back on her FXR4 again. The complete overhaul and Andrews cam has changed the sound of the bike so Abby will have to go accustomed to the new "Cat" as she fondly refers to her bike.

Plasmaman

Plasmaman · « **Reply #31 on:** January 18, 2010, 05:28:47 PM »

Back on the road again. We only have 270 miles logged so the bike is not completely tuned yet. It seems strong and should get even better once broken in. The vibration we hoped to cure remains but has changed and is smooth at highway speed. As you gear down and begin losing RPM you can really feel it in the pedals. All in all, I believe we helped the bike and will learn more after we pass the magic 500 mile break in period.

Plasmaman

Plasmaman · « **Reply #32 on:** January 18, 2010, 08:26:19 PM »

We would appreciate hearing from some of the FXR riders concerning how their bikes feel at various RPM. It is a difficult task to verbally describe the way your bike feels but maybe you can let us know if we are expecting too smooth a ride from the FXR. This bike had very worn motor mounts when we first purchased the bike. The vibration began prior to changing them out and it has never been the same. The old mounts allowed the engine to shake similar to an Electra Glide at an idle and the bike was smooth. The new mounts are much more rigid. We have done a total rebuild on the engine including balancing the crank and all new bearings, rods, pistons, etc. My 2003 iron mounted Evo Sportster is smoother than the FXR. Any input will be appreciated. Most vibration on deceleration and less than 2400 RPM, smoother at 2800-3000. We will not test the higher RPM's until break in is finished.

Regards, Plasmaman & Abby

Chains · « **Reply #33 on:** January 18, 2010, 09:00:07 PM »

Don't know if we have any UPS members or not, if we do they know how poorly UPS handles your goods. If the item was insured then UPS has to repay them for the damages. I have dealt with UPS numerous times and as long as the insurance was in place and you have the damaged goods and packaging, they pay up. Do they play football with your goods yes, do they cover them if you can 100% prove them at fault, yes, but they take months to settle up. Sounds like you have a good motor and all is good too bad for the shipper.

sadunbar · « **Reply #34 on:** January 18, 2010, 09:37:04 PM »

Quote from: Plasmaman on January 18, 2010, 08:26:19 PM

We would appreciate hearing from some of the FXR riders concerning how their bikes feel at various RPM. It is a difficult task to verbally describe the way your bike feels but maybe you can let us know if we are expecting too smooth a ride from the FXR. This bike had very worn motor mounts when we first purchased the bike. The vibration began prior to changing them out and it has never been the same. The old mounts allowed the engine to shake similar to an Electra Glide at an idle and the bike was smooth. The new mounts are much more rigid. We have done a total rebuild on the engine including balancing the crank and all new bearings, rods, pistons, etc. My 2003 iron mounted Evo Sportster is smoother than the FXR. Any input will be appreciated. Most vibration on deceleration and less than 2400 RPM, smoother at 2800-3000. We will not test the higher RPM's until break in is finished.

Regards, Plasmaman & Abby

We've bought an FXR4 for Sheila in late summer. I've probably put 500 miles on it myself. I have to say it rides very smooth with virtually no vibration at all. The bike is virtually stock...

110tHunDer · « **Reply #35 on:** January 18, 2010, 10:42:35 PM »

I gotta agree with Scott. My FXR3 is at least as smooth as my two rubber mounted TC's, if not more so. There's no objectionable vibration from the bike, whatsoever, at any RPM. Mine is also stock, except for a Ness air cleaner.

Plasmaman · « **Reply #36 on:** January 18, 2010, 10:58:32 PM »

:nixweiss:You guys are making us cry. Abby's bike was smooth as well but it changed. Somewhere around $2500 spent and we still have not found and fixed the problem. The only parts not replaced that go round and round are the clutch plates, compensator and alternator. They were all disassembled and inspected for cracks, wear, chips, metal shavings, etc and appear ok. The entire engine has been totally rebuilt with balanced crank, new rods, bearings, pistons, pins, bored jugs, new rings, valve job and new motor mounts. There just isn't anything remaining that we can think of that will cause the nasty shakes. We surrender and will ride the bike as she is unless someone out there comes up with another idea.

Many thanks for your thoughts.

Plasmaman

Plasmaman · « **Reply #37 on:** January 18, 2010, 11:04:57 PM »

One last thought.... Do they make different motor mounts that fit that bike. Primarily the front mount. Maybe a much softer one would remove the vibration.

Plasmaman

Twolanerider · « **Reply #38 on:** January 19, 2010, 10:29:44 AM »

Quote from: Plasmaman on January 18, 2010, 11:04:57 PM

One last thought.... Do they make different motor mounts that fit that bike. Primarily the front mount. Maybe a much softer one would remove the vibration.

Plasmaman

No great difference in motor mounts that I'm aware of. But the Velva engine stabilizer links are a consideration. Rather than the solid links they're an isolated link. They can make a small difference in transmitted vibration.

Plasmaman · « **Reply #39 on:** January 24, 2010, 08:01:05 PM »

:jalapeno:Yea, Abby is happy again. Almost 400 miles on the new engine now and it is so much better. Vibration free, NO, but not much and smooth at road speed. Guess we have to say we were successful with the rebuild. I don't think we will ever know what was causing the excessive vibration but what the heck, it is gone. Hope to go over the 500 mile mark this week and will then have the timing and carburetor adjusted. Can't wait to feel how the Andrews cam has changed the acceleration. Thanks for all of the past hints and help.

Plasmaman

Fired00d · « **Reply #40 on:** January 24, 2010, 08:10:46 PM »

Quote from: Plasmaman on January 24, 2010, 08:01:05 PM

Yea, Abby is happy again. Almost 400 miles on the new engine now and it is so much better. Vibration free, NO, but not much and smooth at road speed. Guess we have to say we were successful with the rebuild. I don't think we will ever know what was causing the excessive vibration but what the heck, it is gone. Hope to go over the 500 mile mark this week and will then have the timing and carburetor adjusted. Can't wait to feel how the Andrews cam has changed the acceleration. Thanks for all of the past hints and help.

Plasmaman

Glad to hear that!!!

Ride Safe,
Fired00d

110tHunDer · « **Reply #41 on:** January 24, 2010, 08:28:37 PM »

Great news, Plasmaman! Gotta admire your tenacity on this! Glad you're happy with the results!

ltank · « **Reply #42 on:** January 25, 2010, 01:42:25 PM »

Hi,
I have a 2000 FXR4. It vibrates more noticably if in 5th at a low RPM about 2000 rpm. I usually run mine pretty good up to about 4800 prm when running through the gears with no problem. When I first got my bike the wife complained about the vibration. I told her she was crazy but one day I wore some shoes instead of my boots and there was a big noticable difference in vibration that was felt on the foot pegs but at no time was the vibration sever. There are the front motor mount and mounts in the swingarm and rear of transmission that clould be a probllem. There are two stabilizers. One athr front motor mount and one between the heads by the carb. make sure they are aligned and not broken. If the motor flywheels were out of balance the shop should have been able to tell you how much they were out of true before being rebuilt.
Ltank

Plasmaman · « **Reply #43 on:** February 03, 2010, 08:38:21 PM »

We now have the 500 mile break in period completed. Abby's bike was running ok but just not as good as it should considering the work done on the engine. We found a minor problem causing a major issue with fuel/air ratio. The "donut gasket" that connects the carb to the intake manifold was not seating correctly and causing a lean mixture. Hard to start, some backfire back through the carb, lack of snap when you add throttle. We found it by spraying a small amount of Chemtool B-12 around the gasket while the bike was running. An obvious change in RPM took place and we knew the gasket was bad. After replacing it, an immediate improvement in performance and starting was noticed. Abby will need to be careful with this bike until she gets the feel of the new found power. It will very quickly get sideways and fishtail down the highway if too much throttle is applied. IT FEELS GREAT. Thanks to all of you who have followed our problems and offered solutions. I truly believe we are on the road again and ready for Big Bend, Texas in the spring. Plan to ride that area April 9-18 if any want to meet up.

Regards,
Plasmaman

Artlee · « **Reply #44 on:** February 04, 2010, 09:46:32 PM »

Great news on the bike! Forgot the trick of spraying the carb to find a leak, thanks for the memory.
Going to Big Bend, good for you! Was there in 98, it is awesome there. Would LOVE to go back and ride those West Texas roads again. Ride safe.

Plasmaman · « **Reply #45 on:** February 06, 2010, 09:17:23 PM »

The weather was cool (40 deg) but clear so Abby got to ride "The Cat" today. It appears that the main jet is sized too small for the engine modifications so will increase to a 195 main and maybe go up to a 49 or 50 pilot jet. The miles per gallon may suffer with the changes but if you make the bore bigger and more cam you will most likely give up a bit of mileage for the increase in performance. This bike had consistently gotten around 50 mpg. Haven't had the weather or time to log enough miles to see the new mpg. Our weather is not predicted to be bike weather all next week. Yes, I know you snow birds are in the garage until spring. Sorry, it won't be much longer. Riding Texas has some advantages.

Plasmaman

fxr4mikey · « **Reply #46 on:** February 11, 2010, 05:54:20 PM »

what a journey you've been on with this bike!!

Glad that it's back together and running well ...

I didn't go back and re-read all of the posts in this thead .. so I just mention this ... you did or didn't have the engine / frame alignment checked or adjusted ?

I have an FXR4 ... no vibration of any sort that one would consider 'unusual' or bothersome ..... I'd call it more of a buzz that runs through the bike. I ride it hard at times. When the road is open and the urge hits me, I don't hesitate to take it to the rev limit through the lower 3 gears, after that I'm usually out of road.

Best of luck with it from here !

Plasmaman · « **Reply #47 on:** February 11, 2010, 11:01:13 PM »

In answer to the alignment question, I don't think that any high tech alignment was ever done. As I have mentioned in past posts, all mounts and stabilizers were replaced. The engine was cranked with mounts loose in hopes that it would seek its own sweet spot. If you have specific points on alignment please share. The bike is so much better now that we once again enjoy riding The Cat. It is only at the lower RPM range that the foot pedals really talk to you. Road speed is ok. Someone up north left the gate open and Texas has 9 inches of snow. I am 68 years young and never have I seen that much snow in the Fort Worth west area. I have the 195 main jet ready to install and go ride the bike but not until we see some sunshine. This has been a strange and colder winter here in North Central Texas. Hang in there, the sun will shine again.

Plasmaman

fxr4mikey · « **Reply #48 on:** February 12, 2010, 07:14:37 PM »

Quote from: Plasmaman on February 11, 2010, 11:01:13 PM

In answer to the alignment question, I don't think that any high tech alignment was ever done.

As far as I know, there is actually a JIG that is put on the bike that is used to align the engine in the frame. I know they have this and use it for the larger bikes such as RK's ... friend of mine and some buddies went together and bought the alignment jig and did their bikes.

I don't know if the alignment is for vibration reasons or to make sure that the torque doesn't casue the bike to not go straight down the road if the engine is not straight inline with the frame.

As I have mentioned in past posts, all mounts and stabilizers were replaced. The engine was cranked with mounts loose in hopes that it would seek its own sweet spot.

I'm no expert here, but I'm pretty sure that's not the correct way to approach this. Check the maint. manual for replacing the front motor mount, you'll notice instructions about the alignment of the torque arm at the bottom to the frame and the one on the top between the cylinders and the backbone.

I'm not trying to cause you concern, I know you've been all over this bike, I'm only throwing out ideas that come to my mind that you may or may not have tried or be aware of. Since you are still experiencing some vibration I'm just trying to assist.

If you have specific points on alignment please share. The bike is so much better now that we once again enjoy riding The Cat.

I am Glad to hear that ...... my manual is out in the garrage, I'll get it this weekend and review ... but I'm sure that I read about that when I had my bike apart for my build and was putting the front mount back in.

It is only at the lower RPM range that the foot pedals really talk to you. Road speed is ok. Someone up north left the gate open and Texas has 9 inches of snow. I am 68 years young and never have I seen that much snow in the Fort Worth west area. I have the 195 main jet ready to install and go ride the bike but not until we see some sunshine. This has been a strange and colder winter here in North Central Texas. Hang in there, the sun will shine again.

VERY weird winter, we have been getting rained out here in South Carolina, now it's snowing like crazy. The news said that today 49 of 50 states have measurable snow TODAY !! Go figure !!

Plasmaman

Plasmaman · « **Reply #49 on:** February 15, 2010, 10:43:24 PM »

FXR4Mikey, thanks for the input. I do not own a service manual for the bike. My mechanic friend does have one which I can borrow and read up on the alignment issue. Our weather has remained cold with the roads just now really drying out. We should be able to enjoy a ride by mid week. If I learn more and make changes, I will give you an update as to the results.

Thanks,
Plasmaman

fxr4mikey · « **Reply #50 on:** February 24, 2010, 06:25:54 PM »

Best of Everything with it !!!!!!!!!!!!!!

Plasmaman · « **Reply #51 on:** March 21, 2010, 06:17:13 PM »

Things were good but just not as they should be so more investigation and a few upgrades. We have noticed a smell when parking the hot bike. Could not locate it. We decided to have the "time by ear" checked against the "timing light". The mechanic found the cam sensor beginning to melt. The dealer timed with a not working properly timing light and that began a wild goose chase of finding what the hell was wrong now. Long story, but will just say we found out what had happened and made the proper adjustments. Dealer also found Vacuum advance switch out of tolerance and replaced. I have ridden the bike about 60 miles and feel that all is well. Even the vibration we fought for so long has just about disappeared. Look out Big Bend, Texas. We ride April 9th to that area. Abby is thrilled to once again have "The Cat" ready to roll. Thanks for all of the past postings which assisted in finding and repairing various issues. Abby's Engine is done.

Regards,
Plasmaman

fxr4mikey · « **Reply #52 on:** March 22, 2010, 08:49:18 PM »

WOW, what a journey !

Glad to hear that all is working well now !!!

Yall sure got some STICK TO IT in ya, lots of peeps, maybe me too, would have given up on that bike. Good on ya's !!!

Yall ride SAFE !!!!!!!! and have FUN !!!!!!!!!!!!!!!!!!

Plasmaman · « **Reply #53 on:** December 12, 2010, 03:10:03 PM »

Yea, we finally found the problem. A chance visit to another bike shop in our area led to a conversation with a really sharp and super nice mechanic. Abby briefly explained about the vibration problem and the long list of things we had done to find it. He asked permission to ride the "CAT" and Abby agreed. When he returned he said "I believe I can fix it". Although doubtful, we agreed to let him try. Remember from our past posts all of the things we had tried including to a total rebuild of the engine and balancing the crank. We left the bike with Scott for a couple of days to test his magic. When we returned Abby rode the bike and was amazed. It was like new and with the rebuilt engine it screamed and was smooth. Scott had installed a velva ride front mount, unbolted the engine and cranked it up to allow it to center. Then he did a complete realignment of engine, wheel, etc. That did the trick. After spending countless hours, thousands of dollars a sharp young mechanic trusted his abilities and solved the problem. He has since been delivered large quantities of Abby's famous cookies. Many of the things we had done were needed and the total package has left Abby with a really fine FXR4. Thanks for all of the input from you guys and gals.

Plasmaman

ltank · « **Reply #54 on:** December 13, 2010, 10:01:05 PM »

Hi Abby,
I am sad that you have such problems on you bike. Having the rebuilt should have fixed the motor. When replacing the motor the primary gets disconnected. I am sure that you inspected the primary/clutch/tranny. A loose primary chain can cause vibration. Loose/worn motor mounts or swingarm/tranny mounts can also cause issues. I had a 89 FXRS new and my current used FXR4 and have not had the problems that you have. I wish that i could be more helpful.
Ltank

FXR2evo99 · « **Reply #55 on:** December 13, 2010, 11:38:37 PM »

CONGRATULATIONS!!!!!!!!!

Tim

Author Topic: Abby's Engine (Read 20447 times)