Thermostat replacement gone bad (missing hardware)

[ouch1011]

Hi all!

I've had my 07 FJR1300AE for a few years now and, aside from basic maintenance, I've enjoyed just being able to ride it. However, it developed a coolant leak some time ago. So, earlier this year, I took it apart to find the leak and found that the thermostat housing o-ring was leaking. After taking it apart and seeing how close I was to getting the headlight housing out, I decided to also do what I had been thinking of doing for a while--having the headlight retrofitted with proper projector headlamps. So, I took it apart enough to get the headlight housing and the thermostat apart, then put in back in storage while the retrofit was being done.

Fast forward a month or two, the headlight is finished and looking great! But, when I went to put it back together, all of the fasteners and hardware that I had taken apart is gone without a trace.

Screws, bolts, nuts, plastic fasteners...all gone. I think my roommate threw them away. Anyway, shortly after that, I tore my right Achilles tendon and have been unable to do much for months, until now! I really want to get the bike reassembled and back on the road, but I'm feeling a bit overwhelmed on where to even start sourcing all the fasteners I need to put this thing back together. I know I get get an assortment of JIS bolts and nuts, but its the plastic fasteners and all the little specialty items that I'll need, plus the fact that it has been over 6 months since I took it apart and I don't really remember what fastener to use where. I'm pretty sure I still have all the brackets and body parts, its just the fasteners I'm missing. Hopefully someone can give me a reasonable place to start or a good resource on how to get going on this. I've included a few pics to show the bike's current condition...maybe that will help.

Thanks in advance!

https://www.supermotors.net/getfile/1122475/original/20171022_135650.jpg

https://www.supermotors.net/getfile/1122476/original/20171022_135712.jpg

https://www.supermotors.net/getfile/1122477/original/20171022_135725.jpg

https://www.supermotors.net/getfile/1122478/original/20171022_135743.jpg

 

[RossKean]

While a parts fiche (lots of them on-line) will list all of the parts you need, it won't be easy to figure it out. To be honest, the best way to do this would be to have a really GOOD friend with a Gen II bike agree to work with you for a day. Basically take his apart to the state where yours is and record/photograph all the removed parts. Look them up on a website such as

https://www.boats.net

and order everything you need. Take LOTS of pictures.

Do you know anyone with a GenII who might be willing to work with you while he/she scopes out some of the things you don't get to frequently? There are, for instance, a couple of spiders and electrical connectors that should be checked out. (Definitely easier with the nose off.) Not to mention servicing the windshield mechanism and the PVC "gasket" that keeps some of the water and dirt out of the nose of the bike. I have had the nose off my bike twice - had to clean and then re-stick the gasket and had an electrical issue. Not that tough to do but there is a lot of frigging around and lots of parts.

This post might help:

https://www.fjrforum.com/forum//index.php?showtopic=116788

Good luck!

 

[escapefjrtist]

Kinda echoing RK...go through individual parts fiches and review the fasteners used for each sub-assembly. When you get right down to it, there aren't that many different fasteners, although having some familiarity with the puzzle helps a bunch.

Figuring them out will be time consuming but not impossible. Best source will be one of the on-line parts houses.

Good luck!

--G

 

[mcatrophy]

Can't give you a list, however I took quite a lot of pictures during the fairing removal of my '06, you might get some help from them. Looky here.

 

[ouch1011]

Thanks guys!

I don't really participate much with car/bike groups as I find driving/riding to be a lot of fun on my own, so I don't really know anyone else nearby who would be willing to take apart their bike just to let me see how it all goes together. I guess this will be my winter project.

 

[Niehart]

ouch1011, go to the Pacific Northwest site on the forum and ask that question? Carl or someone with help you instantly.

 

[El Toro]

If it were me, Id just go to the www.mrcycles.com website and order what I was missing. Heres a start.

https://www.mrcycles.com/oemparts/a/yam/50045b2ff8700209bc79400e/headlight

You know what youve got ... so order the other stuff. Most of the items look like theyre a couple of bucks or less per piece. Nothing is horribly expensive.

 

[FTL900]

On Sunday I watched 2 parts techs at a Harley dealership go over the exploded view of a parts fiche for an hour trying to find a specific screw. Those things are not easy to read. They finally gave up- found the insert that the screw threads into, and then went to their parts bins and located a screw that fit the insert.

 

[El Toro]

Its not a Harley, and most of us are smarter than Harley Techs.

If you cant figure out what you need from the exploded view, you may not need to be doing the R&R anyway.

Maybe this is a geometry issue. Some day the parts fiche may be a virtual automated R&R. That might be easier, or at least reassuring.

I was looking for a grommet on the F6B parts fiche the other day. I thought it would be with the other body panels. It was not. I was surprised to find it with the engine page instead. It secures a plastic panel on the frame, behind which the engine resides. Sometimes you have to be creative, and you always have to be persistent.

A weekend mechanic who cant find something on the fiche might be excused due to their amateur status. A Technician who works as a Technician for a living but cant find parts using the fiche is just flat incompetent.