Am I missing anything??

[ponyfool]

I have gone through the service manual to see what parts need to be replaced. Am I missing anything? When it comes to the internals, I figured I'd replace pretty much everything that shows even a hint of wear. That's why I have so much of the tranny on the list.

GASKETS

Exhaust Gaskets 4FM-14613-00-00

Cylinder Head Cover Gasket 5JW-11193-00-00

Oil Pan Gasket 5JW-13414-01-00

Middle Gear Case Cover Gasket 5JW-15462-11-00

Generator Cover Gasket 5JW-15451-11-00

Pickup Rotor Cover Gasket 5JW-15456-11-00

Pickup Rotor Screw Gasket 90430-08143-00

Clutch Cover Gasket 5JW-15461-11-00

Pinion Cover Gasket 5JW-15463-01-00

O-RINGS

Throttle Body fuel intake O-ring 5FL-14147-00-00

Oil Pump Delivery tube O-ring 93210-14003-00

Oil Relief Valve Sensor O-ring 93210-15566-00

Oil / Shaft Crush Washer 214-11198-01-00

Pickup Rotor Cover O-ring 93210-32172-00

Valve Cover Coolant O-ring 93210-18417-00

Inner Water Pump O-ring 93210-33133-00

Starter Motor O-ring 93210-25711-00

Clutch Bolt O-ring 93210-06632-00

Oil Cooler O-ring 5JW-13473-00-00

PARTS

Shift Fork (left) 5JW-18511-00-00

Shift Fork (right) 5JW-18513-00-00

Shift Fork (lower) 5JW-18512-00-00

2nd Gear Pinion 5JW-17221-00-00

3rd Gear Pinion 5JW-17131-00-00

4th Gear Pinion 5JW-17141-00-00

5th Gear Pinion 5JW-17151-00-00

Main Axle Circlips 93440-31172-00

1st Gear Wheel 5JW-17211-00-00

2nd Gear Wheel 5JW-17221-00-00

4th Gear Wheel 5JW-17241-00-00

5th Gear Wheel 5JW-17251-00-00

Drive Axle Circlips 93440-32063-00

Upper Shift Fork Guide 4XV-18531-00-00

Lower Shift Fork Guide 5JW-18535-00-00

Crank Case Bolts 90119-09001-00

Clutch Bolt Retention Washer 90215-25218-00

Shift Shaft Circlip 99002-10600-00

Rivets 90269-06081-00

 

[odot]

Gasket sealer and O-ring lube..............

 

[HaulinAshe]

You are the one that gets to look at everything, so only you can say for sure. But it seems like a lot of tranny parts and NO bearings. If there is even a hint of metal fragments having floated around, I would replace the major tranny bearings too.

In any case, I would replace this one:

18 93310-33306-00 BEARING

Those little suckers are very difficult to judge wear and damage.

Be sure to make a trip to the Honda dealership and buy a big tube of HondBond. Even Yamaha mechanics know that Honda makes the best gasket sealant on the planet.

 

[ponyfool]

I didn't even think of the bearings.

There is no evidence of metal fragments: Nothing on the drain plug magnet, no visible scoring, etc. But clearly there must be with the amount of wear on the dogs and gears.

But, #18 looks like a good one to replace while I'm in there. I'll also look for other open bearings as well.

 

[HaulinAshe]

I would be most concerned about metal trapped behing the shielded support bearings on the ends of the tranny shafts. Slivers of steel (for some sick reason) tend to accumulate between the outer bearing surfaces and the case. Over time, those slivers grind their way into the bearing and do damage.

I would seriously consider pricing the bearings and weigh the cost. It's a good amount of labor to replace them all, freezing the bearings, heating the case etc. But when you are in that deep and you know damage has been done, it's a lot of piece of mind for typically less than $200.

Just my $.02

You'll know what feels right when you get inside the case. Maybe the local dealer will cut a restock deal with you so that you can have the bearings on-hand, and return them if not needed.

 

[ponyfool]

You'll know what feels right when you get inside the case.

I'm in the case (THREAD WITH PICTURES), and the entire thing looks brand new except the wear on the shift fork and gear dogs.

I've had a couple friends that have worked on bikes in the past stop by to take a look, and they were all stunned at how clean and new the engine looked on the inside.

Remember, it only has 12,000 miles on it and has had probably 5 oil changes in that short time frame.

 

[HaulinAshe]

Great pics!

I zoomed in on a couple and can't see any signs of metal fragments in some typically tell-tale spots. IMO, you should be fine with only replacing #18.

Good luck!

 

[mike25]

Pony, I doubt that you need all the gear sets. But do think about

having the second gear dogs undercut.

 

[charismaticmegafauna]

I don't know about under-cutting the dogs (yes, I know about it -- not sure it would apply in this case?)?

But...I'd certainly shift through all the gears by hand before the cases are put-together -- upside down (like you have it) paying special attention to the second gear dogs engagement. Your FJR may be the one-out-of-thousands that got a bad shift drum (or, has other problems) keeping it from fully engaging second gear?

You'll want to visually verify that it's shifting perfectly before you button-it-up.

 

[radman]

That dog damage is actually pretty minimal, but combined with that obviously junk fork, would make things interesting. I would say the fork is the big reason the bike would get outta gear though. Hardly any sign of galling on the fork ears that actually contact the slider surface. Since you're in there though, no reason not to replace the bad gears. Bearings should be mint, no chunks floating around means very unlikely anything wrong with them.