fJR Broken gearbox... [update 18-12-06]

[feef]

Riding home today, I noticed a couple of occasions where it felt like the gearbox was jumping out of gear, but it didnt change the gear it was in.

In accelerating out of a roundabout, and changing up the box, I hear a scrunching noise, like a false neutral, and lost all drive. At the same time, the gear selector went all flappy.

Got the bike home after running back and forth from home to Milton Keynes (only about 30 miles), to get my car and trailer.

Anyone know what the situation is with the warranty on a bike that's 3 years and 2 weeks old? or have I now got an expensive paper weight?

I suspect the selector mechanism has sheared somewhere inside.

a
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[Kickstart]

Hi

How long was the warrenty on it? Has it been dealer serviced from new? If it is a 3 year warrenty and has been serviced by a Yamaha dealer then Yamaha might come to an arrangement.

All the best

Keith
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[feef]

got a full service history from new, but I'm not sure what the warranty is. I need to check that.

Even if the warranty is less than 3 years, I'd make a call on 'fit for purpose' if their gearboxes are suffering "serious mechanical failures" within such a short space of time.

a
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[Paddy Blake]

It sounds like it might be just a spring.

[Kickstart]

Hi

Doubt you would get anywhere at all on that. Outside warrenty pretty much leaves you at the mercy of their feelings.

Guy at work had major hassle with a Peugeot his sister had where the gearbox went pop at 15 months old. Peugeot would have nothing to do with it. He compared that to his Lexus where the ignition switch wore out (well outside warrenty, well over 100k), and Lexus replaced it for free as it should not have worn out.

All the best

Keith
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[sickpup]

[feef]

had a look at the FJR service manual, and I suspect it could be the
shift-shaft pawl or stopper leaver that has failed.. or even the entire
end of the shift-shaft mechanism that has come adrift.

Luckily, I can check that by draining the oil, taking a couple of engine
covers off, and removing the clutch..

the service manual does mention checking the pawl, return spring and
other bits in there, for wear, and to replace if required.. it's as good
a place as any to start I spose.

if it's the shift-drum mechanism, or anything deeper, it involves dropping the engine out, and dropping the crankcase off the bottom of the engine, which includes taking the heads and barrels off

I hope it's the shift shaft and pawl :S

a
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Mudskipper wrote: feef, that is such a beautiful post that it gave me a lady tingle
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[feef]

taking the clutch out of the FJR presented me with this:
https://www.kickingtyres.com/pics/fjr/DSCF0460.sized.jpg

I thought "yay" only a spring has come adrift..

unfortunately not.

The end has sheared/fractured off the selector drum
this...
https://www.kickingtyres.com/pics/fjr/DSCF0465.sized.jpg
https://www.kickingtyres.com/pics/fjr/DSCF0466.sized.jpg

is supposed to go on the end of there...

https://www.kickingtyres.com/pics/fjr/DSCF0463.sized.jpg

The end of the selector drum is welded onto the shaft, and the weld has failed. Looks like a shear/fracture. Despite the shaft sitting a good 10mm inside the selector star it's only the very end of the shaft that has weld on it.

I'm going to consult the service manual, but I suspect this is rather major

a
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Mudskipper wrote: feef, that is such a beautiful post that it gave me a lady tingle
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[Paddy Blake]

Is the middle of the drum treaded because i dont think the part should be
welded on


Paddy.

[feef]

[sickpup]

So the fault is in the first area I say check and I get no karma! Not that I'm bitter mind.

Engine out, flip over, sump off, crankcase off.

[feef]

[Paddy Blake]

I dont have a manual but you might be able to take of a plate at the bottom
of the engine for access to the gearbox,If so then you need to take out the
shaft that the selectors go on then take out the selectors and pull out the
drum.

Paddy.

[sickpup]

[feef]

the sump's coming off anyway, as I've not idea what bits have fallen down there as part of the fracture.. once it's off I'll see if I can get the selectors out....

a
____________________
Mudskipper wrote: feef, that is such a beautiful post that it gave me a lady tingle
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[feef]

[sickpup]

That would be all the gearbox except the gears, shafts and selector. Just the pawl on the end.

[feef]

[Paddy Blake]

[sickpup]

Feef doesn't like us anymore Paddy. Time for some more Guinness.

[feef]

[woodyfjr]

Bloody hell that a pain how many mile on the motor?

Anyway the shift drum assembly looks like it's fitted in from the side, know I dont know if its possible to jiggle it out as the selectors sit in the grooves. When reassembling fit the bearing last to give a bit more movement.
Look at page 5-110.
If is doesnt work it looks like a motor out to me.

Good luck
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[feef]

[woodyfjr]

The selectors are at the back and at the top of the motor so it would be hard.

If you want to get your hand in, the main shaft (clutch & gears) comes out from the side just may have enough room to get the drum refitted.

Page 5-110
____________________
If you don't pay your exorcist you can get repossessed.

If you have to rev it! Don't Buy it!

[feef]