Gearbox advice needed

[NTXFJR]

Question for the FJR gearhead afficianados. My son abused 1st gear on his '13 a bit too much by riding with a non properly releasing clutch. The 1st gear dogs are nicely rounded over now, it would appear that a new gear set is in his future. So my question is, can gears be pulled and replaced without pulling the motor and splitting the cases? TIA

[Festus]

I replaced a shift fork and gears on a '13 and documented it on this forum.

viewtopic.php?t=3138&hilit=jolene&start=80

Starting around page 5, I think. Might be helpful to him. I don't think it could be done without taking the motor out, but maybe it's possible. It would make a lot of things a lot more complicated. Much easier to take the engine out (it's not difficult) and flip it over, then you'd working down into things instead of up from under it.

[Hppants]

AFAIK - you have to split the cases to get to the transmission and do anything. I cannot see how that could be done without removing the engine from the chassis.

[Festus]

AFAIK - you have to split the cases to get to the transmission and do anything. I cannot see how that could be done without removing the engine from the chassis.

Maybe I'm remembering wrong, it's been so long since I even thought about this, but I thought splitting the cases involved the crank area. If that's correct, then no, you don't need to split the cases. You just need to take the pan off the bottom to get to it. Of course the clutch and everything else in the area needs to come out.

[Dan Cooper]

If you recall, some shops were replacing the entire gearset on 2016 - 2020 scooters without removing the engine from the frame.
Wouldn't think it would be any different on the 2013 - 2015 scooters.

dan

[Festus]

If you recall, some shops were replacing the entire gearset on 2016 - 2020 scooters without removing the engine from the frame.
Wouldn't think it would be any different on the 2013 - 2015 scooters.

dan

Good point. I didn't have a lift and had never done it before or even seen the parts and how they work together. I didn't even know exactly sure what was broken. I imagine with the right tools, lifts, instructions, it could be done. I had none of that

[Hppants]

OK - first, a disclaimer: I've only disassembled one FJR motor in my life. That doesn’t make me an expert. But IIRC, I don't know how you could remove the shift forks without splitting the case.

Now - I just consulted my '13-'15 Yamaha Service Manual:

1. Page 5-98. To remove the shift forks, you must remove the Drive Axle Assembly (duh). To remove that, the first step is to remove the crankcase. Side note on this page (Remarks) "Seperate, Refer to Crankcase on page 5-78.

2. Page 5-78, Crankcase. To remove, step one, remove "Engine".

Again - I don't know how you would be able to remove the drive axle and the main transmission shaft without splitting the cases. And I'm quite certain you can't split the cases without removing the engine from the chassis.

Maybe someone who's done it can offer more.

[Festus]

Maybe someone who's done it can offer more.

That would be me. See linked post above, with photos. I know I'm getting old and forgetful, but let me know if there's a photo in that thread where I split the case.

[Hppants]

Maybe someone who's done it can offer more.

That would be me. See linked post above, with photos. I know I'm getting old and forgetful, but let me know if there's a photo in that thread where I split the case.

I'm not trying to be argumentative, but what am I missing? I don't think you would have to remove the cylinder head. But under the cylinder head, the crankcase is in two pieces. You remove the lower piece to expose the transmission (and the crankshaft). The upper piece contains the piston cylinders and supports the upper half of the crankshaft and the transmission.

I guess you could try to remove the lower crankcase upside down or with the motorcycle laid on it's side, but that seems a bit challenging to me.

I watched your thread (with envy BTW) when you did the work. Taking it apart ain't nothing. Putting it back together (and it works - for years) is something.

I feel pretty ignorant not being able to follow what you are getting at????

[Festus]

I think there's just a misunderstanding of terms on my part. Originally, when this was done, there was mention of having to take it much further apart. According to your drawing, I did take that off and the photos indicate I did take that off.

[raYzerman]

Yes you split the case, and no way to do it without doing that. The bottom half of the case contains half of the crankshaft bearings and your pics clearly show it was apart. The oil pan is bolted to the lower case. This is all best done while the engine is out and upside down so gravity keeps the crankshaft, etc. held in the upper half of the engine. I'd think helluva mess if you did it in situ unless you have some way of holding the crankshaft up against gravity.....
Of note, there are some bolts holding the cases together that are one-time use, ie, when torqued originally the sequence involves stretching the bolts.... technically you're supposed to use brand new ones.... (don't tell anyone but on other bikes I've known some who didn't and it was OK as far as we know). Damned bolts aren't cheap.

[NTXFJR]

Mama Yam had a safety recall 3 or 4 yrs ago to replace gears on some gen 3 bikes that apparently were prone to shattering under certain high stress events. The dealer did mine under warranty, I don't know why but I had the impression that they did it without dropping the motor. What you all are describing makes perfect sense though.

[raYzerman]

If you're talking about the 6 speed recall for second gear, the engines were dropped and cases split, entire gearset replaced as a cassette. I have the technical instruction sheet the dealers got if ya like... dealers were paid 15 hours labour.

[huron52]

Way back when on the XS11 forums some people had problems with the second gear slip. Some of them turned the motorcycle up side down and removed the bottom, removed the problem gear (s) and or cut them. bolted it back together. Not sure how long the fix held together.

[Hppants]

Way back when on the XS11 forums some people had problems with the second gear slip. Some of them turned the motorcycle up side down and removed the bottom, removed the problem gear (s) and or cut them. bolted it back together. Not sure how long the fix held together.

I think in theory that would also be possible with the FJR. To me, the difference is that for the FJR, the engine is a stressed member of the chassis. By the time you remove the tupperware, the exhaust, and everything else, you are literally only 4 bolts away from removing the enging and working right side up.