grumpypoos Gen 1 transmission repair

[NTXFJR]

Also - woke up today. My back is very pissed off at me. I'm sure the motor is happy. I was going to go over and start cleaning parts but not sure. Might be an easy Sunday for me. All my parts are scheduled to roll in next week. I'll get the main piece of this puzzle Tuesday.
How exciting! I bet she will run like brand new when I'm done.

Deep stretches.

That lil feller you see in the pic lives in Keller

 

[audiowize]

This looks to be progressing nicely. This forum certainly benefits from ambitious members like you!

 

[TomInPA]

At some intermission, you might want to contact 08FJR4ME about his WynPro block-off plates for the PAIR system

Any benefit to doing this other than cleaning up things?

Not much other than it makes service a lot easier. I doubt you'll see a noticeable performance increase, but it sure is nicer when you go in next time for plugs or a valve check.

 

[grumpypoo]

That lil feller you see in the pic lives in Keller

Perfect I'm assuming you aren't too far out then. Shop is behind Central High School. I'm cleaning the throttle bodies. I'll probably want to put the engine back in either next weekend (assuming parts will allow it) or the weekend after next.

I have some money with your name on it my good sir if you come to help.

 

[grumpypoo]

This forum certainly benefits from ambitious members like you!

Without this forum not sure I would've done this. It was those before me that have me the confidence I could put it back together without too many left over bolts!

 

[FJRPittsburgh]

Sure wish I lived closer to you. I'd love to help out and observe. That's what makes tech days so enjoyable. Also the experience of some on this board is so valuable.

 

[grumpypoo]

To be fair if I thought for one second I could do it under the bike I would've. I know better than that tho

I'll probably get a live stream going when its time to disect!

 

[grumpypoo]

Got my transmission today. My goodness the parts look very solid. Minimal wear. I'll post pics tomorrow so I can get some HD

 

[grumpypoo]

Got the rest of the stuff today.

Going to begin the tear down!!

I won't be able to put it back together until I get my bolts tho but at least I'll be able to confirm the problem and rebuild it.

 

[grumpypoo]

Did the valve check

I'm within spec on all valves

Not sure what exact measurement because mine is increments of .05 I'll probably redo cylinder 4 #2 exhaust valve cause it's on the loose end

 

[mcatrophy]

Did the valve checkI'm within spec on all valves

Not sure what exact measurement because mine is increments of .05 I'll probably redo cylinder 4 #2 exhaust valve cause it's on the loose end

If it's loose but within spec, I'd leave it, they tend to go tighter with time. Loose is safe, tight is when you'll do damage.

 

[wfooshee]

Just because it's on the loose end doesn't mean anything. In spec is in spec. If you don't have a previous valve check to compare it to, and to show change over time, it's a non-issue.

There's no such thing as "more in-spec."

 

[grumpypoo]

Well I broke the god damn clutch basket trying to undo the bolt this repair just got expensive.

Any method for removing that bolt?

The 30mm one that is

 

[grumpypoo]

Actually the clutch boss. Not too bad of a replacement part.

 

[grumpypoo]

It appears someone's opened this before.

3 stripped Allen bolts on the oil pan...

I'm not excited to see inside at this point.

 

[HotRodZilla]

How long have you had this bike? You saw problems from day one and bought a warranty that wasn't honored? I'd be making a LOT of noise at my Attorney General's Office.

 

[grumpypoo]

I've owned it for roughly 4 months now.

I will be making noise after I get this fixed. I cancelled my warranty as it's useless.

Status update:

1. Broke the clutch boss (Read the god damn manual grumpy)

2. Bought a few more tools and an air compressor (I sold mine awhile back thinking I wouldn't need it, but kept my impact thank god)

3. Removed the clutches and will be measuring them tomorrow.

4. Performed a valve check and was within spec on all.

5. Removed the bolts from the oil pan (three were stripped to hell and back someone has been in here before for something no reason for it to be stripped)

Tomorrow's todo:

1. Remove the oil pan and clean it real good

2. Remove necessary components to split the cases.

3. Split the cases

4. Rebuild the transmission

From this point forward my step by step will start. The manual is fantastic and if you're going to do this kind of stuff buy it, but if you're like me you wanna see exactly what you'd see in person.

There are great threads relating to this exact issue and I suggest you study it like you'll have an exam.

Stay tuned for the step by step to start tomorrow!

 

[Mihalis fjr]

The tool for the clutch boss is the:90890-04086 part number from Yamaha,as you see in the manual..

As about the clutch basket if you mean the N.1 in microfiche,yes,it is expensive..$475.

https://www.partzilla.com/parts/search/Yamaha/Motorcycle/2005/FJR1300+-+FJR13T/CLUTCH/parts.html

Here is a used clutch basket from ebay in a very good price only $88 and it looks like brand new!03-05 is the same part number.

https://www.ebay.com/itm/04-2004-YAMAHA-FJR1300-FJR-1300-CLUTCH-PLATES-WITH-BASKET-E47-/371378835922?hash=item5677e751d2:g:WRIAAOSw-vlVnw53&vxp=mtr#shpCntId

 

[Geezer]

Regarding the stripped oil pan bolts, there have been instances of over-tightened drain plugs which then strip the threads in the pan, leading some people to replace their oil pan.

 

[wheatonFJR]

Regarding the stripped oil pan bolts, there have been instances of over-tightened drain plugs which then strip the threads in the pan, leading some people to replace their oil pan.

Yes, some were over tightened because they tightened per the Specs in the official Yamaha Service manual.