Possible transmission problems or?

[Fred W]

Yeah, I think you're going to be fine here. I fully understand your anxiety, this is a big deal. But they (the managers) seem to be understanding it too.

I doubt that other guy's engine had a loose bolt. They may have just told the warranty (insurance) company that so they would cover the repairs in the warranty terms. Yours may very well have a loose something-or-other too.

 

[grumpypoo]

I dropped the bike off today. it really hurt to leave her with them, but hopefully she comes back and will grant me many more smiles per miles.

I did ask them to take pictures of the following.

1. Engine cams in time before anything is removed

2. All broken pieces

My FJR did however join the list of tickers. I suspected it but it was very much noticeable now.

 

[RaYzerman19]

I don't know what to say except I would want it clear to all parties what happens in this process BEFORE any $119/hr. teardown takes place.......... you had every right to be nervous about taking her in. 9 hours is $1000+...........

 

[grumpypoo]

Yea we shall see what they say. I did tell him the second warranty says no stop touching the bike and call me and I will come pick it up as is. At that point I'll ***** until I get one of the following..

1. Tear down waived

2. Tear down waived + free t-shirt

3. Tear down waived + steak dinner

4. Tear down waived + a free pass to kick some bodies *** there.

I did have the chance to sit on the 2016 FJRA while I was there. Must say nice bike. It's a little taller than my FJR. The led lights are real nice. Exhaust is still too quiet. I didn't get a test ride I begged.

 

[HotRodZilla]

I like option 4 and want to see the video!

 

[grumpypoo]

I like option 4 and want to see the video!

Will do, but let's hope it doesn't come to that!

I should see pictures start rolling in today with everything. Tomorrow i'll get to see the broken forks! How exciting.

 

[grumpypoo]

So got a call from the dealer all 4 techs they have authorized to do this kind of work said it doesn't pop out of gear at all. So I go up there and ask if I can test it.

It's gotten worse now it goes right into neutral and won't go back into second unless I go back to first the back to second.

I informed the service manager. He told me to take it home and try to see all the conditions that must be met. Idk what to do guys.

Anyone in Texas with an engine crane? I think I'm going to fix this myself.

 

[rPGoatBoy]

You didn't really think they were gonna honor the warranty, did you? Sorry about the **** luck, but at least you're somewhat enthused about doing it yourself. I hope you get your money back for the warranty; it should cost about half of that for the parts you'll need. Write a ****** Yelp review for their business practices, inform the BBB, etc. but don't lose too much sleep over it, it's not worth it.

You won't need an engine crane, just a motorcycle jack to lower the engine down from the frame. Then you and a buddy can lift the bike up over the motor. Same buddy can help you lift the motor onto a bench, it's ~230lbs IIRC, so find a big buddy.

Good luck, and do lots of reading. We're here if you get stuck.

 

[grumpypoo]

They did waive a fee for me so everything they "did" was free.

Yea I've pulled an engine before so I'm really confident in my abilities. My buddies are what shall we say? Lazy?

I'll probably have to Jerry rig something.

So we know the forks and dogs are 100% **** at this point. So what am I looking at in parts? ~$400 sound about right?

Obviously this is not a weekend project.

 

[grumpypoo]

Also anyone have a link for a service manual? Paper none of that digital poo.

 

[grumpypoo]

Just bought a complete transmission for the FJR. $124.97 shipped.

This is fantastic because now I just get the bolts some lube and sealer (torque wrench as well mine broke). I could probably get this done in a weekend maybe into the week!

Afterwords I will be taking the broken pieces to the dealer and showing them I'm not some bumbling ****** that has zero idea what is being said.

I will be starting a new thread the day the parts arive. I'll be doing a repair not a rebuild but will have left overs for my use later down the road.

Last thing FJRfourm thank you so much for the wife open arms I was greeted with and maybe one day I will have the opportunity to meet you fine gentlemen!

 

[FJRPittsburgh]

Good luck with the repair Grumpy. Positive wrenching vibes sent your way. Keep us in the loop.

 

[wfooshee]

OK, now you do need my thread. I got the engine out and back in, without a lift, by myself.

The only place to actually by the manual is Yamaha, or finding a used one somewhere either on the forum (like I did) or on eBay. As they say on TV, "Not sold in stores." I'm not sure the Hanes manual they released covers splitting the case.

 

[grumpypoo]

OK, now you do need my thread. I got the engine out and back in, without a lift, by myself.The only place to actually by the manual is Yamaha, or finding a used one somewhere either on the forum (like I did) or on eBay. As they say on TV, "Not sold in stores." I'm not sure the Hanes manual they released covers splitting the case.

I just read that entire thread. Very good information and thanks for the part number on those bolts. Now I need an angle guage as well. First question for you my good sir!

Does the front end really need to come out or can the engine just slide out the side?

 

[rPGoatBoy]

I was able to pull my engine without removing the front end. Remove the front fender or else the exhaust studs may scratch the **** out of it. DAMHIK.

 

[grumpypoo]

I was able to pull my engine without removing the front end. Remove the front fender or else the exhaust studs may scratch the **** out of it. DAMHIK.

Excellent!

I bought an '06 tranny because at this point why the **** not?

I'm 90% sure it can all be swapped in which case I will because reducing the RPMs sounds fun and I sort like the idea of a Gen 1.5 bike possibly the first of its kind?

 

[Fred W]

I'm 90% sure it can all be swapped in which case I will because reducing the RPMs

No you won't. The 1st, 2nd and 3rd gen transmissions are all the same gear ratios. It was only the middle gear ratio that changed in 2006 slightly taller and reduces rpm.

Your 2nd Gen replacement parts should work OK in your 1st Gen bike.

 

[grumpypoo]

No you won't. The 1st, 2nd and 3rd gen transmissions are all the same gear ratios. It was only the middle gear ratio that changed in 2006 slightly taller and reduces rpm.
Your 2nd Gen replacement parts should work OK in your 1st Gen bike.

Could I just do a complete swap then? My concern is the VSS is the teeth the same on the middle gear?

Also status update - Transmission is worse I rode it to work today. Did not want to move out of second to save it's life. It will be going into the "workshop" (my mommas garage) today and begin dis-assembly. I'm not sure if i'll drop the motor just yet, but i'll get the fairings and all that jazz out of the way first.

Needless to say i'm very pissed off I took it in and it was usable now it's more broken (maybe it finally gave out or the "techs" made it worse?).

 

[Fred W]

Hmmm... not sure about swapping "transmissions". I thought that you would be swapping over the gear shafts and gears, forks and shift drums. Someone with more experience inside the split cases could tell you more about swapping the middle gear over.

 

[wheatonFJR]

No you won't. The 1st, 2nd and 3rd gen transmissions are all the same gear ratios. It was only the middle gear ratio that changed in 2006 slightly taller and reduces rpm.

Your 2nd Gen replacement parts should work OK in your 1st Gen bike.

Could I just do a complete swap then? My concern is the VSS is the teeth the same on the middle gear?

Also status update - Transmission is worse I rode it to work today. Did not want to move out of second to save it's life. It will be going into the "workshop" (my mommas garage) today and begin dis-assembly. I'm not sure if i'll drop the motor just yet, but i'll get the fairings and all that jazz out of the way first.

Needless to say i'm very pissed off I took it in and it was usable now it's more broken (maybe it finally gave out or the "techs" made it worse?).

So all this problem and the Techs couldn't recreate the issue?

Interesting.