From: car377@cbnewsj.cb.att.com (charles.a.rogers)
Subject: Re: FJ1200; did they make filter changes difficult ON PURPOSE?
Organization: AT&T
Date: Fri, 24 Jul 1992 17:09:08 GMT
Summary: Seals, locating tabs

In article <5108@transfer.stratus.com>, cdodson@beast.cac.stratus.com (R. Craig Dodson) writes:
> In article <14nifdINNfm9@grapevine.EBay.Sun.COM> batman@batcave.EBay.Sun.COM  
> (Karl Elvis MacRae - Ministry of Silly Walks) writes:
> >     ...
> > 	dark by the time I finished, so I really could not tell if
> > 	everthing was back together correctly.
> >     ...
> > 	OIL SQUIRTED ALL OVER THE PLACE from the oil-filter-thingy, at
> >     ...
> > 	So the question to those of you with FJ's is, what's the 
> > 	most likely thing I did wrong (Aside from trying to change
> > 	my oil in the dark, which was obviously a bad idea)? 

Very good.  Following the factory service manual instructions isn't
a bad idea either. There are *lots* of things to screw up on a modern
bike if you just try to figure it out as you go along.  I had a buddy
demolish his engine cases (not an FJ) because he used a lot of force
to separate them when he still hadn't removed all the securing bolts.
In the manual was a large caution block indicating that the final
securing bolt was *underneath* an access cover inside the engine,
something not obvious if you didn't know where to look.

> >     ...
> The first thing you did wrong was not to make use of the clever drain
> screw in the oil filter housing. 

Correct.  Also, be absolutely sure you don't overtighten this screw
when re-installing it.  The Housing is soft aluminum and if you 
deform or damage the threads, it will leak like crazy. Don't ask me
how I know.

> the rest of the way out of the drain hole. Loosen it too fast and it all
> splashes out the back onto the exhaust, but you know that already.

Make a small funnel out of the spout of one of those plastic gas-line 
antifreeze bottles.  Use that to direct the oil away from the pipes.
Put a small board under the right leg of the centerstand so the bike
tilts slightly to the left so the oil runs to the drain hole.

> As fas as your leak now, I would guess that you either lost the rubber gasket
> that inserts into the edge of filter housing, or you caught the kickstand
> switch wire in the housing, preventing a good seal. 

Also, be sure the locating tab on the edge of the filter housing is correctly
positioned in its receiving slot.  If it isn't, you can crack the housing
by tightening the bolts, or prevent the housing from seating against
the engine case.

Also, be sure you haven't lost the flat washer for the spring that forces
the filter element against the engine case when the housing is 
installed.  The flat washer keeps the spring from digging into the
filter element, and oil usually sticks it to the element so it's
hard to see (especially in the dark) and it gets tossed along with
the old filter.  This won't cause your leak, but it's another common
occurrence with seat-of-the-pants oil changes.

> Good Luck - and read the owners manual sometime :-)   (RTFM as they say)

And while you're at it, get and use the factory service manual.  It
doesn't cost much more than the filter housing, and the first time you
*don't* break something because you used the manual, it pays for itself.
Lots of FJ fasteners have torque requirements that are *real*.  You'll
break or deform something if you don't comply with them.

Chuck Rogers
car377@druhi.att.com