And the journey begins

[Joe2Lmaker]

Yamaha had the foresight that very few of the connectors will mate up to the wrong wire.

It's a Poka-yoke thing

 

[wfooshee]

Thanks for playing, Walt.
I'll pull the rear wheel, FD assy. and U-Joint before continuing. The shifter bracket is a "must be removed" item and is already off. Shifter is nice and filthy, and "grabby" as well. Lots of cleaning to do before reassembly, but that's well down the road from now.

Coolant sensor, BTW, is in the coolant pipe above the valve cover. Keeping track of all the wiring is gonna be easier with Juicy's suggestion of taping and labeling. Fortunately, Yamaha had the foresight that very few of the connectors will mate up to the wrong wire.

And I guess the clutch hydraulics are out, too?

 

[BikerGeek99]

Glad to see you're on the way to having the FJR back on the road, RH.

And thanks for documenting the process.

BG

 

[BwanaDik]

Hard to get off with one hand tied up holding the airbox up and leaving just one hand free to remove jerk off the hose.

Kant BELIEVE you guys missed this one. :lol: :lol:

Go get 'em Howie

 

[RadioHowie]

Thanks for playing, Walt.
I'll pull the rear wheel, FD assy. and U-Joint before continuing. The shifter bracket is a "must be removed" item and is already off. Shifter is nice and filthy, and "grabby" as well. Lots of cleaning to do before reassembly, but that's well down the road from now.

Coolant sensor, BTW, is in the coolant pipe above the valve cover. Keeping track of all the wiring is gonna be easier with Juicy's suggestion of taping and labeling. Fortunately, Yamaha had the foresight that very few of the connectors will mate up to the wrong wire.

And I guess the clutch hydraulics are out, too?

Yep! Cut that hose and ready to go. :assassin:

 

[ShinyPartsUp]

[/COLOR]

[SIZE=18pt]DAY TWO......the ugliness commences[/SIZE] 


I just got in from working 7.5 hours without more than a pee break [SIZE=14pt]on my day off![/SIZE]


So I wanted to see how the manatee man was doing...


"I know most of you bastards are out riding right now, so here's a great, big :****: you to each and every one of you! "


NOT ME, so here's a second :****: to all you bastages...

 


"Those not out riding are trying to knock off some items off their "Honey-do" lists, so for all you pussies, a great big :****: you to you too!"


I'm not letting my kids come back when they grow up -- who's the puss Howie?

 


"It's about 110 degrees out in the garage, and it's got a western exposure, so it's gonna be a hot bitch all day. Oh, humidity is about 963%, too. So I'm taking my time and taking cool-down breaks between tasks."


Stop yer bitchin and do what I did -- buy an AC unit at a garage sale and put it in the window. No window? Use those pry bars and make a hole! Wus...

 


Then you went blah blah blah, yada yada yada...

 


"Cool-down period is almost over...drinking LOTS of cold fluids to keep up spirits (nothing adult, mind you) ...."


[SIZE=14pt]Well! There's your problem![/SIZE] Cerveza por favor?

 


Last advice: be careful of the gas :focus:

 


Glad ya finally got going, and I wish you luck as I follow along and harrass you. If you need practical advice such as the above let me know. :****: :friends:

 


Oh yeah -- hurry up. I got a short attention span.

 

[BwanaDik]

Looks like you should have got one of these for your shop (garage?). I got one the minute I moved to the South

 

[RadioHowie]

Howie
That sure is a pretty green King (Rex) sitting on the other side of your garage.

I hope you plan to take it for a spin sometime this weekend just to keep things in focus.

This is supposed to be fun!

 
Just got back from a nice 50 mile "Lakes" ride just before sunset. We got LOTS of lakes in my little corner of the universe and there's nothing like roads following shorelines to make up for all the straight asphalt here in Flori-DUH.

 

 
I REALLY needed that ride! Had to "blow off some stink" as MissusHowie refers to it when you're suffering from cabin fever. In my case, it's garage fever.
 
Let Rex stretch his legs and sharpen his claws. DAMN that bike is a hoot! The perfect hooligan bike. And when that Muzzy is singing at 11,000 rpm, it's a joy to hear.
 
Silver Streak was pissed. He wants to go play, too.

 
 
 
 

 

[RadioHowie]

[SIZE=18pt]DAY TWO......the ugliness commences[/SIZE]

I just got in from working 7.5 hours without more than a pee break [SIZE=14pt]on my day off![/SIZE]

So I wanted to see how the manatee man was doing...

"I know most of you bastards are out riding right now, so here's a great, big :****: you to each and every one of you! "

NOT ME, so here's a second :****: to all you bastages...

"Those not out riding are trying to knock off some items off their "Honey-do" lists, so for all you pussies, a great big :****: you to you too!"

I'm not letting my kids come back when they grow up -- who's the puss Howie?

"It's about 110 degrees out in the garage, and it's got a western exposure, so it's gonna be a hot bitch all day. Oh, humidity is about 963%, too. So I'm taking my time and taking cool-down breaks between tasks."

Stop yer bitchin and do what I did -- buy an AC unit at a garage sale and put it in the window. No window? Use those pry bars and make a hole! Wus...

Then you went blah blah blah, yada yada yada...

"Cool-down period is almost over...drinking LOTS of cold fluids to keep up spirits (nothing adult, mind you) ...."

[SIZE=14pt]Well! There's your problem! Cerveza por favor?[/SIZE]

Last advice: be careful of the gas :focus:

Glad ya finally got going, and I wish you luck as I follow along and harrass you. If you need practical advice such as the above let me know. :****: :friends:

Oh yeah -- hurry up. I got a short attention span.

Jebus Chrispies....learn how to use quote-backs for cryin' out loud!!!

 

[RadioHowie]

[SIZE=18pt]DAY THREE..........and a new mystery![/SIZE]

Just finished an 11 hour "holiday" at the office and got home with just enough energy to pull the rear wheel, final drive and U-joint.

No photos, as they've been well documented on the forum, except for the U-joint. You must pull the left footpeg and shifter assembly to access the "dust guards" covering the U-joint, but it slips right out of the tranny.

However, after removing said wheel and final drive, when I picked up the drive by the ring & pinion case to carry it over to my parts cache, something hit the floor with a loud "clang". I've looked in the FSM in the "Shaft Drive", "Swingarm" and "Rear Wheel" section of the FSM and can't figure out what it is and/or where it goes.

Anyone recognize this?

Flange on one end, slightly larger diameter just below the flange and same witdh as a BIC lighter.

What the hell is it? I can't find a picture reference in the FSM, on FJRTech.com or FJR1300.info.

 

[Bustanut joker]

Not sure there Howie but it looks like the inner carrier for the diff. IIRC it slides in from the inside.

Now if ya' done this two weeks ago when I had mine tore apart

:jester:

 

[Geezer]

It looks like the part in the middle of the parts diagram for the drive shaft. It doesn't have a reference number in the parts fiche so I don't know what to call it. I think this is what Bust was referring to also.

 

[RadioHowie]

Not sure there Howie but it looks like the inner carrier for the diff. IIRC it slides in from the inside.
Now if ya' done this two weeks ago when I had mine tore apart

:jester:

So we all know I'm stupid and clueless, but where the hell in this exploded diagram of the Diff is this suckah??

Do you mean here?

NOT a tight fit, and quite a bit longer than the hole is deep.

Signed,

Befuddled in Florida

 

[Bustanut joker]

Yeah thats the spot I was thinking.. But that diagram sure doesn't show it to size does it...

Just checked FJR Tech(as I know you also have) Sure looks to be right

Purdy sure that's the right spot, but I ain't all that smart neither

Always something eh bud.

:jester:

 

[RadioHowie]

Okay, took a look at a parts fiche as Geezerboy did and there it is...unreferenced with a part #...

How in the hell did that miss showing up in the FSM?

I guess when Grumpy gets here in 2 weeks, I'll take a look at his diff and see if it just sits there, all stupid and loose.

Edit: Oops...there it is! Over on the right, Part # 32 "Guide Collar". Sorry Mama Yama.

 

[Bustanut joker]

Okay, took a look at a parts fiche as Geezerboy did and there it is...unreferenced with a part #...
How in the hell did that miss showing up in the FSM?

The Editor an I went drinking that day....

Gosh I did something helpful again? .... I... I think I wet myself a little

:jester:

 

[user 213]

Sorry I've been absent. Missed this thread and was a little tired Sunday from my ride back from Spokane on Friday.

Bust is right on the sleeve. Mine fell out too. And yes, it's way easier to pull the motor with the rear diff and u-joint out of the way first.

FYI- Put a floor jack or something that rolls under the motor and when you unbolt it, lift the frame off of the motor. For this reason you may want to get some help, or set up some pully system. I used a chain hoist that I had already. Made it easy to control the ups and downs when trying to line up the new motor with the lower motor mounts.

Looking good RH. Keep plugging away at it. Oh yeah, unplug all the electrical crap up front before you start to unbolt the motor.

 

[RadioHowie]

Sorry I've been absent. Missed this thread and was a little tired Sunday from my ride back from Spokane on Friday.
Bust is right on the sleeve. Mine fell out too. And yes, it's way easier to pull the motor with the rear diff and u-joint out of the way first.

FYI- Put a floor jack or something that rolls under the motor and when you unbolt it, lift the frame off of the motor. For this reason you may want to get some help, or set up some pully system. I used a chain hoist that I had already. Made it easy to control the ups and downs when trying to line up the new motor with the lower motor mounts.

Looking good RH. Keep plugging away at it. Oh yeah, unplug all the electrical crap up front before you start to unbolt the motor.

Eric,

Did you pull the forks off to make room to pull out the front? Would it make it any easier?

 

[Gizmo]

Howie...You are one ambitious SOB I hope you're gettin' some help dude. Looks like it will be ugly, at least for a while. Good Luck and keep us posted on the progress...

 

[user 213]

Did you pull the forks off to make room to pull out the front? Would it make it any easier?

I didn't. Depends on what you have to lift it with. I tossed a strap over the rafter and used the chain hoist, but in a pinch a come-a-long would work too. There isn't a lot of weight to lift w/o the motor there. It becomes more of a wiggle to the right angle job when getting things lined up again.