2nd Gear got bit by the Dragon

[maddad]

Just got back from a trip South to the Dragon, Diamond Back, Moonshiner 28, etc. etc. Great trip.... however...

I just hit about 68,000 miles on the 05. When coming onto it hard in 2nd gear I feel two distinct clunks at around 5,000 and 7,000 RPM. Feels like a tooth is missing out of 2nd gear.

It doesn't do it in any other gear. Can still do a stand up wheelie in 1st. (Okay did it twice, once nearly flipped). Lots of sit down wheelies. Enough bragging.

Looking for some suggestions. It only happens when giving it pretty much full throttle in 2nd. Rode 1500 miles back home without feeling it at all.

Is this potentially 2nd gear, a spring or possibly the clutch going. Would prefer the clutch is this issue as I expected that to be a problem after a good day at the drag strip and had been prepared to replace the clutch.

Thanks.

 

[ionbeam]

If it is only second gear then it is highly likely that you have a bent shift fork. To fix the problem the engine has to come out, the cases split and the gear assembly taken apart. :dribble: Some Forumites have done this repair themselves, some had it done for them and others have bought a used engine for less than the cost of the repair. So, how do you like your 4 speed FJR? Sorry man, you have some hard choices. I have some idea what you may be facing.

 

[RadioHowie]

That 2012 FJR, almost same color as your 05, looking better and better???

 

[03HiYoSilver]

Here are some pics on what is mentioned above:

https://www.fjrforum.com/forum//index.php?showtopic=143918&view=findpost&p=941520

 

[rogdeb]

If it is only second gear then it is highly likely that you have a bent shift fork. To fix the problem the engine has to come out, the cases split and the gear assembly taken apart.

Alan is correct --- as always Just had this problem fixed myself (at the dealership) a few months back. Mine was at the 64k mark.

 

[Chuck35]

For those of you that have had this failure. Do you hit 2nd hard? wheelies?

 

[azitlies]

For those of you that have had this failure. Do you hit 2nd hard? wheelies?

Good question Chuck.

From what I've read, over the years on this forum, it seems to be a result of abuse (obviously) or, in some cases it seems, "hard shifting".

As we've heard from many posters, the dealership (re hard shifting) will always say "keep breaking it in, it will be okay". And in most cases that's true. But it *seems* that in some cases the hard shifting is a result of "stuck" clutch plates, and it continues on and on, eventually resulting in a bent gear dog. At least that's what I remember from PonyFools assessment.

 

[maddad]

Okay, so a bigger job then I expected, but won't be the first time I pulled an engine. Just first time on a bike.

Currently running well, not slipping out of gear or jumping unless I come on to it really hard so I may just leave it for now. See what winter brings and if I have the time to do it this winter or squeeze in the season next summer and plan for it next winter. Time to start babying the thing instead of treating it like a race bike.

 

[lnewlf]

If it is only second gear then it is highly likely that you have a bent shift fork. To fix the problem the engine has to come out, the cases split and the gear assembly taken apart. :dribble: Some Forumites have done this repair themselves, some had it done for them and others have bought a used engine for less than the cost of the repair. So, how do you like your 4 speed FJR? Sorry man, you have some hard choices. I have some idea what you may be facing.

Yup-and rounded off shift dogs to go with it. Second gear is usually where the problem shows up due to the space between first and second. Ham fisted [footed?] shifting will do this every time. The clunk occurs when the gears jump dogs. If you have decent mechanical skills this is doable but involves many hours and big bucks for parts..[a gear can easily run over $200].I did this on a '94 RF900 Sazook and it was a fun project..If you are going to run the poor FJR like a wild man you might want to have a shop undercut the dogs to prevent this from happening again.

 

[rogdeb]

Okay, so a bigger job then I expected, but won't be the first time I pulled an engine. Just first time on a bike.

Currently running well, not slipping out of gear or jumping unless I come on to it really hard so I may just leave it for now. See what winter brings and if I have the time to do it this winter or squeeze in the season next summer and plan for it next winter. Time to start babying the thing instead of treating it like a race bike.

I babied mine for a while till I figured it was safer to get it corrected. The mechanic said it only took one bad shift to start the damage then time took care of the rest of it.

 

[maddad]

Was at the Drag Strip today and was discussing surgery for this Shift Fork. One of the tuners mentioned that he had heard of an alternative approach to doing this and wondering if anyone had any thoughts.

1) A big assumption that it's just the tuning fork that is bent and not a lot of where on any other parts.

2) If you pull the Oil Pan, can you see the shifting forks?

3) Is the shaft that the shifting forks rests on removable without taking the engine out of the bike.

4) If you pull out the shaft,

 

[dcarver]

4) If you pull out the shaft,

She'll never get pregnant?

 

[maddad]

Was at the Drag Strip today and was discussing surgery for this Shift Fork. One of the tuners mentioned that he had heard of an alternative approach to doing this and wondering if anyone had any thoughts.

1) A big assumption that it's just the tuning fork that is bent and not a lot of where on any other parts.

2) If you pull the Oil Pan, can you see the shifting forks?

3) Is the shaft that the shifting forks rests on removable without taking the engine out of the bike.

4) If you pull out the shaft, on some bikes the shifting fork will slide out through the oil pan.

Anyone familiar with this or have an engine in pieces that could take a look?

 

[dcarver]

Was at the Drag Strip today and was discussing surgery for this Shift Fork. One of the tuners mentioned that he had heard of an alternative approach to doing this and wondering if anyone had any thoughts.

1) A big assumption that it's just the tuning fork that is bent and not a lot of where on any other parts.

2) If you pull the Oil Pan, can you see the shifting forks?

3) Is the shaft that the shifting forks rests on removable without taking the engine out of the bike.

4) If you pull out the shaft, on some bikes the shifting fork will slide out through the oil pan.

Anyone familiar with this or have an engine in pieces that could take a look?

Have you seen ponyfools' documentation? Try here

 

[03HiYoSilver]

Here are some pics of the Forks:

https://www.fjrforum.com/forum//index.php?showtopic=105278&st=20&p=916062entry916062

https://www.fjrforum.com/forum//index.php?showtopic=105278&st=20&p=915899entry915899

 

[fudgejerkin1188]

Pretty sure the shift forks can't be replaced through the sump. I've changed a complete gearbox on one of my FJRs due to a gear and selector fork issue. Plenty of photos if needed but they would take some digging out. Its not a difficult job but it is very time consuming

 

[dunhamg]

I'd bet it's a combination of a bent shift fork and rounded off dogs on second gear. You will also want to replace 5th gear too. I had the shop do this 4 times under warranty on my '99 R1. Still remember the mechanic couldn't replicate the problem on a test ride. I told him it was only doing it while holding a wheelie in 2nd gear and they said okay and tore it apart. It would only hold up for about 25,000 miles on the R1 so either I've gotten a lot better at shifting or the 5-speed on the FJR is build tougher as I've had no issues in just over 100,000 miles.

Grady

 

[wmadoty]

I have not had to do this to an FJR, but I have had to do this to several used bikes that I have purchased over the years. In my opinion, if the fork(s) are bent, you will be replacing gears as well. I would not recommend trying to go short and cheap with this repair.