2nd gear is bad

DirtFighter · Aug 17, 2015

I just bought an 05 about a week ago. It pops in and out of gear in 2nd...kinda feels like a toothb or two are gone (under anything but the lightest throttle) any way the bike rides fine other wise.

I don't know anything (yet) about these sweet machines and was wondering if an 04 transmission would fit in an 05. I found a complete transmission for decent money but don't know if will cross over. Any help would be appreciated before I buy the gears

escapefjrtist · Aug 17, 2015

An '04 transmission will work but a better upgrade is to install '08 and up 2nd gear parts.

Good luck!

--G

DirtFighter · Aug 17, 2015

Thank you.....Hopefully it is not too hard to fix

JamesK · Aug 17, 2015

Changing transmission parts is a major job, not only will you need to drop the engine out but also tear it down. Unless you're able and willing to do all of this yourself I suggest that a decent used Gen1 engine might be a better option. At least swapping the engine is not rocket science tearing down the engine does require considerably more skill or a significantly higher labor cost.

DirtFighter · Aug 17, 2015

I will definitely consider that...this one has 53k on it now..I have been seeing motors for between $600 and $1000...might even get one with fewer miles on it.

I only paid $2800 for the bike ...so I knew I would have to throw some dollars at it to get it ****

RossKean · Aug 17, 2015

+1 on the engine swap. Way easier and far cheaper unless you are doing it all by yourself. While I will do most work by myself, I think I would draw the line at a gearbox swap unless I had someone with more knowledge to lend a hand. I'm pretty sure I would be OK with an engine swap. Good luck with it!

BkerChuck · Aug 17, 2015

+2 on the engine swap. If you go this route, before installing would be a good chance to check the valves too.

JamesK · Aug 17, 2015

BkerChuck said:
+2 on the engine swap. If you go this route, before installing would be a good chance to check the valves too.

And replace the CCT

rPGoatBoy · Aug 17, 2015

I'm gonna be the (so far) lone voice of dissent and suggest you split the original motor, depending on how mechanically skilled you are. I've done it before, and to me, pulling the motor was more labor intensive than splitting the crankcase halves. If it's just 2nd gear, that's two $70 gears and one $65 shift fork. The rest would be gaskets & o-rings, 10 main bearing bolts, plus the valve shims & CCT you'd more than likely be putting into a donor engine.

You could probably pull it off for ~$300-400. 53k on the original engine is just getting broken in.

Unless of course the previous owner was an ******* and didn't do any PM. If that's the case, another motor is your best bet.

wheatonFJR · Aug 17, 2015

DirtFighter said:
I just bought an 05 about a week ago. It pops in and out of gear in 2nd...kinda feels like a toothb or two are gone (under anything but the lightest throttle) any way the bike rides fine other wise...

I hope the previous owner "owned up" to the issue!

If not they are a slime ball...I hope they aren't on the FJRForum and someone I know. That would be very disappointing.

NMRoadRunner · Aug 17, 2015

Might be just a bent shifter fork or something like that. Take a look fist before you buy anything. You gotta go in there anyway, may as well wait and see what you find in there.

BobbyBlue · Aug 17, 2015

I'm really gonna go out on a limb.....how fat are you ? Do you NEED 2nd gear....this motor pulls like a truck and i skip gears sometimes just cuz i'm not racing....i mean i know what it SUPPOSED to have but c'mon....unless your trying to set new land speed records and you have a good first and third gears....fuggit...for 2800 i'd live with it....put a new CCT and chain in it and ride the **** out of it....you'll never use 2nd to pass ....that's third gears forte....i'd just upshift twice...just my .02....if you live in hills this might be more of a problem admittedly, otherwise i could live without a gear on this bike other than 5th !

Blessings,

Bobby

ionbeam · Aug 17, 2015

BobbyBlue said:
I'm really gonna go out on a limb..... Do you NEED 2nd gear....this motor pulls like a truck and i skip gears sometimes just cuz i'm not racing...

That was my initial thought, you really don't need second gear. Then I checked the OP's location -- CA. There are lots of roads in CA where you do in fact need 2nd gear, well, maybe not need, but 2nd gear sure helps a whole lot. On short rides it's possible to get by without 2nd gear but on long rides up the coast or through the mountains and it would be a challenge.

DirtFighter · Aug 17, 2015

LoL...how fat am I ?....1/8 ton (250..its a phase, I'll be back to 220 in no time)

Yes, I did know about the problem before I bought it. I figured even if I put $2k into it that would put me at nornal price range for a healthy bike.

Holy crap...this thing does pull like a ***** ape...so far so good without 2nd....but it sure would be cool to have that "out of the hole" shot of adrenaline

Mr. BR · Aug 17, 2015

wheatonFJR said:
DirtFighter said:

I just bought an 05 about a week ago. It pops in and out of gear in 2nd...kinda feels like a toothb or two are gone (under anything but the lightest throttle) any way the bike rides fine other wise...

Click to expand...

I hope the previous owner "owned up" to the issue!

If not they are a slime ball...I hope they aren't on the FJRForum and someone I know. That would be very disappointing.

I saw this bike on a Nor Cal Craigslist a week or two ago...and yes, it was being sold with a known 2nd gear issue... There were multiple listings as usual but before the ad disappeared I"m sure I saw it listed as having a "minor issue" and no other specifics. I'm thinking.. what about the g-box problem? Anyway, intriguing project and for me personally, I'd split the cases and fix the trans.. but that's just me. I have the tools and some experience to pull it off without too much trouble. It IS a big project no matter what and we've all seen the pictures on this forum from those who have done it before. Good luck to the OP regardless of the path he takes on the fix.

Mr. BR

TownsendsFJR1300 · Aug 17, 2015

If you decide to repair or replace, the engine has to come out anyway.

There's several threads here to help with the engine breakdown, that is if your familiar/comfy with tearing into a MC engine..

wfooshee · Aug 17, 2015

I went through this last summer when I broke a piece off my shift drum, when I got in there I found some issues with the gear dogs, and was fortunate enough to get donor parts for the cost of shipping. The story of the teardown is here, starting in post 131.

And as stated above, splitting the case is nothin' compared to getting the lump out in the first place. Lots and lots of wires and stuff. Get a shop manual!!!! Sequences are important!!!

HotRodZilla · Aug 17, 2015

If second gear is bad, isn't 4th close behind? I wouldn't just 'let it be,' but that's just me. 2nd gear is my favorite, so I'd really miss it.

DirtFighter · Aug 17, 2015

I am quite fond of 2nd also...it is for sure going to get fixed one way or the other. 4th so far has no symptoms of any problems. I am still getting to know this machine. I figure easy riding for the rest of the summer then tear it down this winter......maybe I get crazy and shoehorn a 350 in it ;-)

Thanks everyone for replying and providing links and what not...much appreciated

2nd gear is bad

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