08 clutch problems

[user 213]

Just got my '07 back for the dealer, "Acton Motor Sports" Fairview, OR. They said the clutch plates looked okay and that they soaked them in oil as directed by the Yamaha rep. I felt a tight shifter for the first few miles until the engine warmed up. One of the directions they had for me was to allow for a good warm up. My honda doesn't require a long warm up period.

Action in Fairview is good people. I've had them do a valve check and some warranty work w/out hassle or problems. Factory Motorsports in Oregon City, not so much. Techs aren't nearly as well trained, but they do great on tire changes. I do always bring in my wheels off the bike though.

FWIW, on warm up, I typically only wait until I hear the idle drop, which IIRC happens about the time it hits one bar on the temp gauge, (on my '04).

 

[FJRed]

Well, I just checked the Yamaha parts fiche at www.ronnies.com and the clutch basket and plates are the exact same Yamaha part numbers from 2003 through and including 2008 so the rumors about an improved clutch basket design for better oiling don't seem to be true.

I bought a new 2007A in February and I was having the same clunky shifting and sticky clutch issues that others have reported. This past weekend, I took the clutch apart, cleaned the plates, and soaked them in oil for about 4 hours. When I took my clutch apart, only the first 2-3 plates had any oil on them at all. The inner plates were completely dry. They didn't have any sticky or greasy gunk on them as others have reported, they were just completely bone dry. No oil whatsoever. After I put the newly oiled clutch back together, the shifting is 1000% better. It shifts smoothly and the clutch disengages easily and completely just like it's supposed to.

BTW, The FJR had just over 600mi on it when I pulled the clutch apart, and Yes, the bike had the correct amount of oil in it. I checked it when I first brought it home.

Based on the fact that the 2008 clutch appears to be the same as the 2007, It seems reasonable to believe that the 2008 could have the same clutch issues as the 2007 and benefit from the same clutch plate oiling fix.

 

[conwest]

...coincidently, I just took mine apart and like FjrFred said, dry in the middle. My bikes shifting/clutch action (12000kms) was even worse this spring over last year...hard to get into first, without stalling and, without going thru the garage wall. However, the outermost and innermost fibre discs were stuck to their steels,,,so much so, they left a mirrored squared pattern on each steel. And, there was a tiny amount of black goo on each of those 2 fibre discs as others have reported. Also, the short push rod was very difficult to pull out...it was dry too, need to grease that baby for sure. I am wondering: did the factory change the oil supply to the clutch housing in order to get more oil to the top end (or somewhere else)? Yes, I am well aware of the valve guide/ oil seals issue of the first gen. ...could it be they just didn`t change the design of those parts but also, increased the amount of oil feeding them? Just a thought...the first gens had no clutch problems. :angry2:

 

[road runner]

I wonder if it is as simple as they skipped the clutch soak to speed up production.

07 is the first year the FJR wasn't special order. So maybe they sold 2 or 3 times as many as 06 and just couldn't keep up.

I wonder what the production #'s are.

Just my .02

A.C.

BTW I had the same problem and the plates were dry. A soak last year fixed it and this year in the spring it still works great.

 

[zenwhipper]

Can a DIY mechanic (me) do this clutch soak relatively easily? Or is this better left to the dealer?

Grazi

Scott

 

[road runner]

Can a DIY mechanic (me) do this clutch soak relatively easily? Or is this better left to the dealer?
Grazi

Scott

The dealer did mine because it was under warranty. I've never done it but it appears to be very simple.

If you do it yourself get a service manual, lay everything out in the order you take it off, then put it back in reverse order. Also take some pics along the way for reference.

From reading other posts in here I would say it is a simple job. If mine wasn't warranty I would have done it myself.

Good Luck A.C.

 

[FJRed]

It's pretty simple. You don't need any special tools. Make sure you buy a new gasket for the clutch cover. The gasket can get "stuck" to the engine case or the cover so when you take the cover off, the gasket can get damaged. It's the large cover on the right side of the engine (as you're sitting on the bike)

Just keep the parts in order as you take them off and them put them back in the same order.

(Don't forget to drain the oil first)

Ed.

 

[conwest]

As a follow up to my earlier post from May 3rd, I finally got the machine all buttoned up this a.m. and took it out for it`s maiden voyage, post oil soak. The clutch and tranny are finally working like they should....feels like a totally different action down there. Each shift (up or down) just snicks into gear...effortlessly and quietly. All those `07 owners with a sticking clutch: don`t think, just move on it!!!!! :clapping:

 

[CigarGuy]

This same thing happened to me with my 07. I took it in for the clunky and sticking clutch. It really did scare me when it kept pulling after I pulled on the lever. I took it to my dealer (PCP Yamaha in Sacramento) and my mechanic Steve knew exactly what it was. He said the R1's were having this same problem for a while. He kept the bike overnight and soaked the clutch plates, and this clutch is smooth as silk now. Props to Steve and to PCP.

It was all under warranty so I would let them do it!

 

[Shadow]

Well, I just checked the Yamaha parts fiche at www.ronnies.com and the clutch basket and plates are the exact same Yamaha part numbers from 2003 through and including 2008 so the rumors about an improved clutch basket design for better oiling don't seem to be true.

It could be true.

Yamaha often replace a part number for all models if they have improved it, providing it will still fit earlier models.

 

[4wlow]

Just put the 08 back together from a clutch plate cleaning and soak. It seems that 08's (at least mine) suffer the same problems as the 07's. It shifts great now. I did have some of the greese on the plates and some dry spots on plates in the middle.

 

[TechJunkie]

My 08 disengages ok, my problem is that at times it shifts very quietly and smoothly and other times it drops into each gear with a much more distinctive thud. I also have times when 1st to 2nd I actually hit the gear and the shifter almost kicks back into neutral. This also happens sometimes going from 2nd to 1st. It is eerie hearing the gear grind. My next few shifts may be smooth as silk after this. I am just now at 600 miles and scheduling the 600 mile maintenance. Could this be the same clutch plate issue or does it sound like something else?

I did take it back to my dealer and the service tech took a ride and said it is fine. Ride it and it will break in. It seems the more I ride it the worse it gets.

All advise welcome!

 

[dcarver]

As a 60k+ 2006 owner with no problems, I read this thread with interest.

If, in fact, the basket, shafts, bearings, and all are the same..

Then it must be a factory assembly change; I have not heard of any 06's having clutch disengagement issues.

Each yearly issue of the FJR seems to have different 'issues'..

At least our final drives don't go into flames.

 

[noob]

My 08 disengages ok, my problem is that at times it shifts very quietly and smoothly and other times it drops into each gear with a much more distinctive thud. I also have times when 1st to 2nd I actually hit the gear and the shifter almost kicks back into neutral. This also happens sometimes going from 2nd to 1st. It is eerie hearing the gear grind. My next few shifts may be smooth as silk after this. I am just now at 600 miles and scheduling the 600 mile maintenance. Could this be the same clutch plate issue or does it sound like something else?
I did take it back to my dealer and the service tech took a ride and said it is fine. Ride it and it will break in. It seems the more I ride it the worse it gets.

All advise welcome!

techjunkie,

I've been reading alot of the genII threads, being a potential buyer and all, and I can tell ya this, the very very very first thing I'd do with a new 08 (or 07), before I even rode it, is to take out those clutch plates and soak them in oil...

I would either do it at the dealers (and stay in a hotel if I had to) or I'd trailer it. Sound ridiculously anal? maybe... but there have been too many reports of bent gear dogs, which are very expensive to replace. And if this "hard shifting" is what's causing this... well why take the chance?

Once these gear dogs are bent, that's it, they don't bend back by themselves, and soaking the clutch plates sounds like an easy thing to do, to avoid the possibility...

Good Luck with it,

 

[TechJunkie]

My 08 disengages ok, my problem is that at times it shifts very quietly and smoothly and other times it drops into each gear with a much more distinctive thud. I also have times when 1st to 2nd I actually hit the gear and the shifter almost kicks back into neutral. This also happens sometimes going from 2nd to 1st. It is eerie hearing the gear grind. My next few shifts may be smooth as silk after this. I am just now at 600 miles and scheduling the 600 mile maintenance. Could this be the same clutch plate issue or does it sound like something else?
I did take it back to my dealer and the service tech took a ride and said it is fine. Ride it and it will break in. It seems the more I ride it the worse it gets.

All advise welcome!

techjunkie,

I've been reading alot of the genII threads, being a potential buyer and all, and I can tell ya this, the very very very first thing I'd do with a new 08 (or 07), before I even rode it, is to take out those clutch plates and soak them in oil...

I would either do it at the dealers (and stay in a hotel if I had to) or I'd trailer it. Sound ridiculously anal? maybe... but there have been too many reports of bent gear dogs, which are very expensive to replace. And if this "hard shifting" is what's causing this... well why take the chance?

Once these gear dogs are bent, that's it, they don't bend back by themselves, and soaking the clutch plates sounds like an easy thing to do, to avoid the possibility...

Good Luck with it,

noob----

I am going to show my ignorance here but what can get bent? If they are bent what behavior would the machine exhibit? Wouldn't this be covered under warranty?

I am not a mechanic but quite able. I have never worked on my machines inside the motor or tranny, this I have left up to the experts. Breaks, bearings, oil and adjustments I normally do.

I would like to sound somewhat knowledgeable when I call the dealer and express my concerns once again.

 

[noob]

noob----
I am going to show my ignorance here but what can get bent? If they are bent what behavior would the machine exhibit? Wouldn't this be covered under warranty?

I am not a mechanic but quite able. I have never worked on my machines inside the motor or tranny, this I have left up to the experts. Breaks, bearings, oil and adjustments I normally do.

I would like to sound somewhat knowledgeable when I call the dealer and express my concerns once again.

TechJunkie,

if you do a search on "+gear +dog" you'll see some unfortunate owners have experienced it popping in and out of gear under hard acceleration. To fix this problem the casings have to be split, engine out of bike etc.

I'm no expert, but from what I've read these gear dogs may be getting bent due to hard shifting and or simply poor shifting technique. Due to the severity of this though, I'd soak the clutch plates and be sure the clutch is adjusted properly and the fluid is clean.

From what others have said it doesn't appear dealers are too excited about fixing the gear dog problems. They are assuming it's from abuse. I believe there's even a guy with an AE that has (had) the problem, so given that it may be simply poor design? So, assume for a second it is design related, then all the more reason to be sure that clutch (and plates) are in top working order...

(edited to add this wouldn't stop me from getting a feej, still hoping to do that, but given others have said soaking the clutch plates has made their's shift so much better, perfectly even, it's most definitely the first thing I'd do then just hope there would be no issues with the gear dogs.

Good Luck with it,

 

[TechJunkie]

noob----
I am going to show my ignorance here but what can get bent? If they are bent what behavior would the machine exhibit? Wouldn't this be covered under warranty?

I am not a mechanic but quite able. I have never worked on my machines inside the motor or tranny, this I have left up to the experts. Breaks, bearings, oil and adjustments I normally do.

I would like to sound somewhat knowledgeable when I call the dealer and express my concerns once again.

TechJunkie,

if you do a search on "+gear +dog" you'll see some unfortunate owners have experienced it popping in and out of gear under hard acceleration. To fix this problem the casings have to be split, engine out of bike etc.

I'm no expert, but from what I've read these gear dogs may be getting bent due to hard shifting and or simply poor shifting technique. Due to the severity of this though, I'd soak the clutch plates and be sure the clutch is adjusted properly and the fluid is clean.

From what others have said it doesn't appear dealers are too excited about fixing the gear dog problems. They are assuming it's from abuse. I believe there's even a guy with an AE that has (had) the problem, so given that it may be simply poor design? So, assume for a second it is design related, then all the more reason to be sure that clutch (and plates) are in top working order...

Good Luck with it,

Noob---

Thanks for the input. I did research Gear Dog and the information was found. I certainly hope this is not the problem. I am a very tame driver and have not even ridden my FJR above 80 and that was blending into traffic on the interstate. I certainly have not ridden it hard.

I called and scheduled 600 mi service for next week. I asked that a technician take it out and verify it. They said they have a couple of technicians that own/ride FJRs and that they would have one of them check it out. I will mention to him that I think the clutch plates need to be soaked. I will also take a copy of the forum discussion. I will mention the gear dog issue and see what he says after his ride.

Thanks again.

 

[Constant Mesh]

It might be helpful to intentionally slip the clutch on occasion to see if the plates might loosen up a bit -- i.e., more easily and completely separate.

 

[otrfjr]

Why in the world would Yamaha allow the same damn thing to plague some of the 08's when they knew about it in the 07's? I understand the huge lead time for production, but Jiminy Cricket... And I know, I know: it is a marvelous machine. My beef isn't with the FJR or its engineers; it's with corporate executives.

Just put the 08 back together from a clutch plate cleaning and soak. It seems that 08's (at least mine) suffer the same problems as the 07's. It shifts great now. I did have some of the greese on the plates and some dry spots on plates in the middle.

 

[Bokerfork]

Why is everyone soaking perfectly warranted clutch plates in oil. My 07 was doing the same thing. Originally the braniacs at the dealer replaced the slave cylinder, which they said was leaking. That, of course didn't help. They supposedly had taken the clutch apart but claimed it looked fine. Some days later after conferring with Yamaha tech support, they took the clutch apart again. This time they looked beyond the outer plates and found the inner plates fried. They put in a new one under warranty and the bike shifts like new. Actually better than new since I had the problem from day one. Since your 08 is under warranty, simply go in, demand a new clutch and accept nothing less. Soaking would be okay if you had almost no shifts on your clutch, but assume the plates have already suffered some damage unless the dealer proves otherwise.