Winter Project - Reviving a Wounded FJR

[CrabbyJack]

No job is complete until at least one finger is buggered up...

 

[dcarver]

Gotta give props to StreetHawk -

this is the most comprehensive engine tear down on the forum yet.

 

[DennisJ]

I hope I never need the process outline here but I greatly appreciate that it is available along with all the other detailed processes posted on the forum. Required reading that I have been following since before the purchase of my '09 that has been invaluable in the small farkling projects I have undertaken.

My thanks to all.

 

[HotRodZilla]

Jeebus...This thing is moving along. I donno that I would ever get that thing back together, so nice job. Thanks for the pics and step by step...Good stuff.

I'm pretty disappointed in Yamaha's shift fork make-up. Those things fail pretty regularly. Make sure you use the updated parts. Supposedly better.

 

[Niehart]

Panman is correct, Yamaha did a up grade on the gears in '08'. Part numbers might just supersede to the new ones but I would check part number.

 

[supertankerm60a3]

Congratulations! Proud of you for getting into the thing. It is always good to see someone fixing their own things. Especially when you have to go that deep.

 

[Yroundrdn]

Thanks for taking the time to post. Learning a lot here...

 

[FJRMGM]

Thanks for taking the time to post. Learning a lot here...

ye, thanks - good job so far.

 

[Streethawk]

No job is complete until at least one finger is buggered up...

You know Jack, I actually did that repairing some garden shears. I was going to say something about that. I've had grease/dirt/oil from Oldsmobile, Pontiac, Subaru, Mazda, Ford, Honda (car and bike), Kawasaki, Suzuki and now Yamaha mixed with my blood over the years. I was getting worried for a bit as my camera skills have been used more than my mechanic abilities.

I DID manage a small scrape on the hand which I'm assuming has "Christened" the project now.

I agree, it's not complete until blood is drawn!

 

[Streethawk]

Many thanks for the Props and Kudos All.

I know I just showed up as an FJR Newbie and BAM! Hit it with this project. You've all been very kind and helpful with tips and advise. Much appreciated!

I wasn't anticipating an actual purchase until next year. With out my Buddy Doug, I'd be less likely to tear this 07 down. Switch the engine, yes. But with his lead, it's a great learning experience and does seem straight forward.

I love giving back to the Community as well. The Old Golden Rule concept. As I really enjoy reading threads like this. I'm glad the PO can follow as well. I told him it would be taken care of!

(Side story: A guy in the HawkGT community here in MD sold a really nice Hawk to somebody in New York. It was transported back north.... and promptly disassembled and parted it out! For no reason other to get more money out of it than he paid!

Ya just Don't Do That!... well, in my world ya don't.)

 

[Grey13]

If / When my FJR starts to have transmission problems I'll be sure to head to MD. You do accept ride-ins right?

Awesome thread!

Ray

 

[bwv]

(Side story: A guy in the HawkGT community here in MD sold a really nice Hawk to somebody in New York. It was transported back north.... and promptly disassembled and parted it out! For no reason other to get more money out of it than he paid!

Ya just Don't Do That!... well, in my world ya don't.)

When you said HawkGT .. "I was like what??" ... i just posted in the "off topic" area about my Hawk GT... But ... mine is 50 and has 4 tires... then I remebered the Honda... Nice bike. But still an odd coincidence...no? same name, same day post... but i digress...

Back on topic...

Thank you for doing this. Your pictures have been an amazing sight and I look forward every day for the next set. Bravo!!!

And now i know where all that whining comes from Theres a lot of square cut gears in there!

I would especially like to thank your Buddy Doug. As a true beleiver in Karma... I know he's getting some big points here !!! GO DOUG!!!!

 

[wingshot]

Awesome Streethawk and kudos to Doug. (Friends always exceed our expectations.)

I been away from the forum for a week and Doug is already halfway done.

This project is going to be complete in time for a Thanksgiving after turkey ride.

What exactly are you going to do when winter arrives??? Oh that's right, pick up a second job shoveling snow to pay for that new shock you are drooling about.

 

[Grey13]

(Side story: A guy in the HawkGT community here in MD sold a really nice Hawk to somebody in New York. It was transported back north.... and promptly disassembled and parted it out! For no reason other to get more money out of it than he paid!

Ya just Don't Do That!... well, in my world ya don't.)

The needs of the many outweigh the needs of the few?

Hopefully parting it out means more Hawk GTs can get back on the road.

Ray

 

[Streethawk]

What exactly are you going to do when winter arrives??? Oh that's right, pick up a second job shoveling snow to pay for that new shock you are drooling about.

Funny Wing! I did buy a snow blower almost two years ago now.... and we didn't get a flake of snow last year!

IF the FJR gets done sooner rather than later, I can always bring the Concours down and remove 9 years of farkles. Prep the bike for a Spring sell.

THEN the Hawk needs to have the steering head bearings adjusted..... but I've had a set of tapered bearings for a few years now. They need to go in.

The VFR, Vulcan750 (wife's), Hawk and Concours will all get oil changes and air filter cleanings.

I've got a fiberglass repair to do on a solo cowl for the Hawk.

I plan on pulling some parts off the Hawk just to clean up.

THEN (insert Mad Scientist Wringing Of Hands) I'll be planning for further farkling of the FJR!

.....um, I've got a few things I can do this winter!

 

[bhendron]

You're not going to leave us hanging, are you?

 

[Streethawk]

Nope.... sorry! Things have slowed down a bit. So, silence means I'm staring out the front window a lot waiting on the delivery dude!

I'll get some pics posted (such as they are) tonight.

The update I have right now is the AE Engine is gone! (FINALLY!!) I had trouble finding a carrier, getting quotes etc...

And some parts are just starting to come in.....

The main thing I'm waiting on now are the replacement gaskets and seals. With luck, I can make some more progress this weekend. If no parts show, I'll start on the swing arm maintenance.

 

[bhendron]

Ok, GOOD! Love this thread!

 

[rogdeb]

Nope.... sorry! Things have slowed down a bit. So, silence means I'm staring out the front window a lot waiting on the delivery dude!
I'll get some pics posted (such as they are) tonight.

The update I have right now is the AE Engine is gone! (FINALLY!!) I had trouble finding a carrier, getting quotes etc...

And some parts are just starting to come in.....

The main thing I'm waiting on now are the replacement gaskets and seals. With luck, I can make some more progress this weekend. If no parts show, I'll start on the swing arm maintenance.

Waitin', waitin' ... waitin'

 

[Streethawk]

I hope to do more work tomorrow after Church....

This week however, I took a half day off from work to wait for the Fed-Ex Freight Dude. "Between 1 and 5pm" they said.

So I wait......

and wait...... 4:45pm he shows. Very nice guy.

I'm Ready!

We get it on a pallet and he says "Do you have the paperwork and payment done?"

um....... No. Customer service Dudette says "The Driver will take your CC info.... that's all you need!"

Driver just smiles, pulls out his phone and makes a call. "You're not the first or last." He says. 30 minutes later we have paperwork hand filled out and he took my payment info and gave it to the lady on the other side of the line.

The Driver gave me more info in 3 minutes than two 20 minute phone calls to "Customer Service"!

It turns out, you can fill everything out on the web site, print and pay right there and attach the paperwork to your box. THEN (if your neighborhood is safe enough) just put the box out on the driveway and Driver Dude will just pull and take it away!

So it's done and cost me about double to ship out than it did ship in.

Major Annoyance! Residential pickup (Cha-ching!) Lift Gate Truck (Cha-ching!) Moon out of alignment? (Cha-ching!) - sigh....

So now I just need to follow up and make sure my refund comes through and move on. So speaking of moving on!

I get a little tag on my door this week from the Postal Service "Sorry we missed you. We have a package and need a signature."

GAH! Just Leave It at the door! UPS does!!

I fill out the form online to have it held til today (Saturday) so I can pick up and sign...... This is Thursday.

Friday (another little "love note") - Sorry we missed you! -

Teasing me!

Saturday, I'm there to pickup my....

STUFF!

What's In the Box?!?!

All KINDS of "Put Together" goodies! Gaskets (I'll BET REAL MONEY I forgot something!!) and some other bits. Including this little green dotted dohickey!

So we are about ready for full re-assembly!

Probably not tomorrow though. I think the swing arm will get some attention........ Photos to come!