grumpypoos Gen 1 transmission repair

[grumpypoo]

I saw the used one I'll be buying on payday.

It was the clutch boss those damn points the screws go in do not make great leverage.

I decided to buy a compressor and it sounds right off

The Allen head is stripped not the actual bolt. A socket and a hammer got them out in one piece. Let's see what today holds in store

Apparently spun auto corrects to sounds

 

[audiowize]

The one thing that you have going for you is that once she's back together, you'll probably never want a different bike!

 

[grumpypoo]

I know!

I confirmed my suspicion it is a bent shift fork and worn gear dog. My phone died so no pictures I'll have to take some when I go to put it back together.

The forks were no where near as bad as I've seen, but the dogs were almost round? Someone was shifting like ****.

I determined it wouldn't have been covered under warranty since nothing was "broke" to cause the issue. I have the cases split and covered under a blanket. I intend on rebuilding the transmission tomorrow and put most of it back together.

I'm hoping to get this out back together this weekend motorcycle gods willing I have all the bolts!!!!

 

[grumpypoo]

Also thank god for impacts.

Saved me a lot of frustration with the middle gear!

Also splitting the cases is no easy task. I was beating the **** out of one of the frame mount bolt passages for a good 15 minutes. Then finally picked the motor up and down until I heard that beautiful seperating sound!

Yamabond is essentially cement and you'll need to be very patient, but it will come off. Whatever you do DO NOT use a steel mallet. I almost ****** up big time thinking I had the rubber one thankfully only partially dented that passage tube thing.

 

[grumpypoo]

Went to buy that clutch housing and ironically it was sold today :|

Did anyone on the forum get it by chance and if so can I buy the clutch boss from you?

 

[Mihalis fjr]

Went to buy that clutch housing and ironically it was sold today :|
Did anyone on the forum get it by chance and if so can I buy the clutch boss from you?

Pm sent..

 

[grumpypoo]

GOOD MORNING FORUM!!

Today I have quite a bit to do with the bike, but we will start on what we came to do.

1. Rebuild the transmission (Real easy)

That's literally all I can do today. Boats.net is taking it's sweet ass time sending me my ten bolts

. I can situate everything to get the case ready for reseal however!!!

Once I get the bolts i'll put the bottom end back together and flip the motor back over. From there i'll wait for my clutch boss and swap that out and then back in the bike she goes!

I'm getting more and more excited everyday, because I know I should be riding in roughly ~2 weeks. That is assuming I haven't lost multiple bolts and or broke more stuff (THE GOD DANG MANUAL READ THE FREAKIN MANUAL GRUMPY)

Also I managed to move the gear thingy the clutch housing spins on.. Don't tell me thats a syncro, because if it is how the hell do I get it back in sync

EDIT:

Also i'm going to try to get good pictures today. I need to upload what I have but can you say lazy?

 

[Canadian FJR]

Sorry to hear that you have to go through this but it sure is a good read. Looking forward to more pictures.

Canadian FJR

 

[grumpypoo]

Sorry to hear that you have to go through this but it sure is a good read. Looking forward to more pictures.

You know at first I was really pissed off to have to do this, but i'll be honest.

I've never been so close to a bike now. I mean I literally have blood, sweat, and tears (from breaking stuff) in this rebuild. I'm your typical garage mechanic (Tho I did automotive professional before I got into IT). So by no means do I have any method for bolt retention I just kinda take a guess where stuff goes (probably really bad, but you know I could care less as long as it works).

I will say I will honestly probably keep this bike forever now. Once it finally dies (Which looking at the engine I have a VERY long time before that'll happen). I'll just yank the motor and rebuild it.

I honestly believe everyone on this forum can do this type of work. It's really scary, but once you split the cases you realize very quickly EVERYTHING only fits 1 way. So it's really hard to botch the job. I thoroughly enjoy the fact that all the electrical connections are

1. Color coded

2. All different shapes (Only goes 1 way).

The biggest problems I will have to over come.

1. Bolts (I have them all in bags, but I have a few sitting on the floor).

2. See number 1.

I'm not sure how some of those before me reused gaskets, because all of mine were complete garbage.

The oil pan gasket looked like trash (amazing it wasn't leaking).

Stator cover gasket looked no existent (explains the leaking).

The thingy were you put oil gasket (I think it's called engine cover 1?) Could probably be reused, but it's $5 dollars at the dealership.

Clutch cover gasket got messed up when I put it on the floor

My thread is lacking in the pictures department, but I will get a lot today. I get in the working zone and forget to take pics from time to time. Thank god those before me didn't have that problem so I can use that as a reference where stuff goes (See above ONLY GOES IN ONE WAY).

 

[HotRodZilla]

I'm glad you're making measurable progress. I'm also glad you are feeling confident. That makes a job much easier. Thanks for the updates!

 

[grumpypoo]

Here is the offender.

 

[TomInPA]

Not so bad as some, but the wear is there. We've seen some really bad looking shift forks.

 

[grumpypoo]

Here is the right side. A little wear can be seen

Here is the center same wear.

This is where I'm at. I need to go buy a T30 socket so I can get the lower gears out.I'll be replacing ALL gear dogs.

 

[HotRodZilla]

Man, from the looks of those forks, I'd be surprised if every FJR with more than 10k miles doesn't have shift forks that look like that. I really hope the 2016 transmission is better equipped. Seems like it doesn't take much to set those things off.

 

[grumpypoo]

Yea so I just literally put the 06 tranny in everything looks the same and it shifts fine. I can't use the drum however because it has a different end?

I've managed to misplace a shift fork so for tonight I'll be done but I will say I have a good feeling about this!

I will say it looks like 1 bad shift will **** the whole thing up. If we take a look here.

We will notice the gear is extremely worn on the edges allowing the dog to slip

Every gear was like this which prompted me to just plop the new one in.

 

[grumpypoo]

Here is the 2nd gear dog.

Notice it's extremely worn around the edges. The pics don't do it justice but the new ones are straight up and down no paint or coating missing.

 

[grumpypoo]

This is where we end tonight the new trans is installed.

Need to find the new shift fork and I'll begin putting this crap back together

 

[TomInPA]

Well done! I hope I never have to pull the engine from the frame.

 

[grumpypoo]

Well done! I hope I never have to pull the engine from the frame.

Thank you! I hope you never have to as well, but I'm willing to bet your tranny will look similar to this. Yamaha did a really bad job with this design. It looks like someone was speed shifting.

 

[grumpypoo]

Hard to believe 44k on the clock and I had to install all new gears and forks.

I expect this transmission to last me forever now because I'll be damned if I do this again