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[indyblue]

'84 FJ1100L 42K miles

It just suddenly started making an irregular "ting-ting" metallic noise.  Starts/runs smoothly, no loss of power but makes horrible noises.
It seems to come and go (I only drove one mile like this, so only a couple minutes to listen).

I know I'll have to open it up and check things, but before I do are there any likely culprits?  At first I thought it was a rod knock because it sounds like something banging, but a tinging/ringing metallic sound (not a knock or thud of aluminum on aluminum).

Could it be a broken valve spring or keeper?  Hoping it's up top, not looking forward to splitting the case although if I do I will go ahead and do cam & starter chains, second gear fork.

If I have to split the case, what other upgrades/replacements should I consider doing?

[Flynt]

'84 FJ1100L 42K miles

It just suddenly started making an irregular "ting-ting" metallic noise.  

I'd bet your exhaust pipes just failed...  they are double walled and the inner rots through and makes an awful racket against the outer pipe.  Simple fix is to change exhaust.  Some have had success with various McGuyver repairs.  You might find good ones if you look hard enough. 

Of course, it could be something else entirely...

Frank

[indyblue]

Well, the noise seems to come from near topside of engine, nowhere near the exhaust.
It almost sounds like a valve bouncing off the top of a piston. 

Be pulling the valve cover off the check cam chain.  Is there any access to the starter chain without splitting just enough to check it?

[big r]

I bet your exhaust failed. Listen to these guys they know what they are talking about. The sound will transmit to different parts of the engine. I would check the exhaust before you start tearing any thing apart. Just saying

[Pat Conlon]

Yep, inner pipe failure on ‘84/85 oem double wall header pipes...... happened to me.

Sounds like hell.

[indyblue]

Thanks, yes.  It is looking more like what you guys are saying.

I took off the chin spoiler and listened as I revved.  Just idling it is very quiete with an occasional rattle-rattle and it is loudest under the bike.  Sounds like it is vibrating against the oil pan but there's definitely no contact happening, gets louder more consistent when revving and sounds internal to the collector.

It has stock black ceramic coated pipes through the stock collector to SuperTrapp slipons.

What are my options to find a new collector that'll fit stock seteup?  This bike is mint condition (always stored indoors) with no mods other than the exhaust and would like to keep as factory as possible.

Will be removing the collector soon, fingers crossed.

[indyblue]

I found this.  Anyone here have experience with these vendors or parts?  How about any stateside?  I see RPMs system, but I don't need the complete system and that one is a relatively radical change (might need to re-jet?).

They both look like robust designs:

For stock replacement:
https://delkevic.co.uk/yamaha-fj1100-1200-84-96-stainless-steel-exhaust-collector-box-oem-compatible.html

Possible compatible upgrade:
https://www.blackwidowexhausts.co.uk/fj1100-fj-1100-exhaust-collector-box-upgrade--gaskets-119-p.asp


Update: sounds like one or more of the downpipes
I like my dark grey coated pipes :-(

[Pat Conlon]

No, no, the problem is not the collector, the problem resides in one of your 4 oem down tubes, aka header tubes.
Your oem steel collector is single wall. If the collector is rusted out, then yea, get the stainless steel Delkevic.

One of the inner wall in your down tubes is broken and rattling....sorry, no fix.

The good news is that all of the ‘86 to ‘95 oem FJ down tubes aka header tubes are single wall and stainless steel....and they are plug and play with the ‘85/85’s

Oh yea, they also do polish up nicely

[indyblue]

No, no, the problem is not the collector, the problem resides in one of your 4 oem down tubes, aka header tubes.
Your oem steel collector is single wall. If the collector is rusted out, then yea, get the stainless steel Delkevic.

One of the inner wall in your down tubes is broken and rattling....sorry, no fix.

The good news is that all of the ‘86 to ‘95 oem FJ down tubes aka header tubes are single wall and stainless steel....and they are plug and play with the ‘85/85’s

Oh yea, they also do polish up nicely

Hmmmm
I like my dark grey coated with my paint scheme.

But those do look nice.

Are those new or used?  Sources?

[Pat Conlon]

FleaBay. Look for tubes that do not have dents in them. (You can’t polish dents out)

They have stamped part numbers at the bottom of the down tube. The numbers end with the numbers 1 thru 4 so be sure you get the complete set of #1, #2, #3, #4 tubes.  
The tubes are bent a certain way to fit the collector box. You need tubes 1 thru 4

You don’t have to polish them....if you like your tubes black, so be it. The point is that the ‘86-95 tubes are single wall and you will never have a inner tube crack again.

Cheers

[Motofun]

You can also "jet hot coat" the headers in different colors.  I did my '85 headers a month before they broke internally.    I was at a rally 500 miles from home when it happened.  I seriously thought I had a bad engine knock but had no option but to ride the bike.  It worked fine for the whole trip.  When I got home I removed the headers to investigate, not knowing of this failure mode.  When banging each pipe I somehow managed to skip #2, doing #3 twice.  That messed with my mind for a week until I decided to re-investigate.   

[indyblue]

Much thanks to all the experienced wisdom here.  It was indeed the pipes , #3.

I ended up buying the Black Widow exhaust setup.  Reasonably priced even with shipping from the UK, only took 4 days to arrive in IN.


It meets all their claims of stock fit as far as mounting points and head connections, however it was necessary to modify the chin fairing slightly.
Filed off about a 3/16" relief for the inner down pipes.


The old SuperTrapp mufflers still fit the same


The sound is much different, I can hear the stereo effect now.  A little quieter when cruising than the original setup.