Need some advice - busy putting an FJ1200 donor gearbox into the FJ1100.
First picture - what is the little machined bit on the selector drum (as circled) which is not on the 1100 drum? I know it's standard from the factory, but what's the purpose?
I don't know the year model of the donor motor.
Second shot - my old selector fork compared to the donor unit. Though it shows some wear on it, will it be okay to use for the next couple of years? There is no way I can purchase a new selector at the current exchange rate and the state of our postal services (will probably go missing at customs).
Note that the motor has done 170 thousand km already.
Why is there a difference on the gear itself just out of interest.
If your replacing the transmission because it's jumping out of gear your old shift forks are probably bent by now. The newer longer shift forks are superior.
Apologies, this "thing" uploaded the same shot twice..
Yeah, I understand the replacement unit but my pocket understands the Rand / Dollar exchange rate better.
Quote from: T Legg on February 28, 2023, 10:30:40 AM
If your replacing the transmission because it's jumping out of gear your old shift forks are probably bent by now. The newer longer shift forks are superior.
Replacing the drum and selector forks. Strangely we cannot see that the original selector fork (2nd gear) is bent though.
Why are you replacing these items?
Im no expert on gearboxes but im sorry to tell that those shiftforks are not good. Also the drum need to be inspected carefully it is hard to see with naked eye use a hi res camera
and look for wear on the groves.The thing you have circled on the drum from the 1200 i think is made for better shifting into second gear. Also take a close look at the geardogs if they
are worn.When i did the engine on my bike i first bought a used gearbox from ebay that turned out to be more worn than the one i already had in the engine.The gearbox i had in my engine
that is a 1200 was a 1100 gearbox that previus owner had installed not sure why he did that but i think at some time the clutchbasket exploded and the gearbox got replaced with a 1100 gearbox . the bike did not have any second gear problem i just wanted a newer less worn gearbox since i replaced almost everything in the engine
Anyway i bought a second complete gearbox on ebay from a 1996 that was almost as new with the longer and stronger shift forks. The grove in the gears i guess is for better oiling.
il post a few picks that show places the drum gets worn
Quote from: Pat Conlon on February 28, 2023, 01:34:15 PM
Why are you replacing these items?
When selecting 2nd and pushing up on the pedal it stays in 2nd on moderate acceleration, otherwise it jumps back to first. I'm just changing the selector forks but the complete gearbox from the FJ1200 just looks better with less wear.
Quote from: Old Rider on February 28, 2023, 01:36:44 PM
Im no expert on gearboxes but im sorry to tell that those shiftforks are not good. Also the drum need to be inspected carefully it is hard to see with naked eye use a hi res camera
and look for wear on the groves.The thing you have circled on the drum from the 1200 i think is made for better shifting into second gear. Also take a close look at the geardogs if they
are worn.When i did the engine on my bike i first bought a used gearbox from ebay that turned out to be more worn than the one i already had in the engine.The gearbox i had in my engine
that is a 1200 was a 1100 gearbox that previus owner had installed not sure why he did that but i think at some time the clutchbasket exploded and the gearbox got replaced with a 1100 gearbox . the bike did not have any second gear problem i just wanted a newer less worn gearbox since i replaced almost everything in the engine
Anyway i bought a second complete gearbox on ebay from a 1996 that was almost as new with the longer and stronger shift forks. The grove in the gears i guess is for better oiling.
il post a few picks that show places the drum gets worn
Thank you so much - nice input from your side especially with the pictures. There is no wear on the drum of the 1200 selector drum and very slightl on the original. The wear on the selector forks worries me a bit as the same wear can be seen on the second gear - the replacement gearbox has no wear or play on the shaft even though the selector fork does show some wear.
Gamut Where on earth do you live?
Quote from: Gamut on February 28, 2023, 01:37:42 PM
Quote from: Pat Conlon on February 28, 2023, 01:34:15 PM
Why are you replacing these items?
When selecting 2nd and pushing up on the pedal it stays in 2nd on moderate acceleration, otherwise it jumps back to first. I'm just changing the selector forks but the complete gearbox from the FJ1200 just looks better with less wear.
Ok, then don't use those short shift forks, use the new longer 3XW forks that came out in 1991 and later FJ's.
Also check the gear for rounded engagement dogs, have it back cut if necessary.
Gamut i asked where you live because i think i still have the shift forks from the 1100 gearbox that sat in my bike when the engine was rebiulidt. And also have shiftforks from the 1200 gearbox that i bought from ebay but did not use because the gears looked worn the shiftforks looks good and my bike when the 1100 gearbox was installed did not have any 2 gear gearbox problems.
You can have them for free.One more thing to check is that the bearing on your shiftdrum runs smooth.
Quote from: Old Rider on February 28, 2023, 02:20:27 PM
Gamut Where on earth do you live?
South Africe - the land of milk and honey (once upon a time long long ago). That is extremely kind of you but you're a very long way away. Thanks very much for the offer though.
Quote from: Pat Conlon on February 28, 2023, 02:48:34 PM
Quote from: Gamut on February 28, 2023, 01:37:42 PM
Quote from: Pat Conlon on February 28, 2023, 01:34:15 PM
Why are you replacing these items?
When selecting 2nd and pushing up on the pedal it stays in 2nd on moderate acceleration, otherwise it jumps back to first. I'm just changing the selector forks but the complete gearbox from the FJ1200 just looks better with less wear.
Ok, then don't use those short shift forks, use the new longer 3XW forks that came out in 1991 and later FJ's.
Also check the gear for rounded engagement dogs, have it back cut if necessary.
Will do some cutting on the gears then it's done. Thanks for that.
Your shift forks on the left look entirely shot to me and I wouldn't be building an engine back up with the ones on the right either unless it was life/death and no alternative available.....
If you are offered better forks for the price of postage then surely thats a sensible approach no?
I checked with a route planner and if you live in cape Town south africa it is 14352 KM or 8886 Miles and estimated time to drive shortest route that
is thru trans sahara desert highway is 191 hours and 25 minutes. That is a little too long ride :biggrin:. But since im coming from the land of santa claus
i will go to the post office tomorow and check how much shipping is to South Africa.If it is not jaw dropping i will send the forks to you for free .
You can PM me your adress and name
This morning i was down in the cellar and found the shiftforks.I was very surprised to find 3 sets of forks ?? .When i split the engine i wanted to change out the 1100 tranmission since the gears and dogs looked a little worn it worked fine, but since the cases was split i wanted to install a less worn gearbox. I first bought a complete 1200 gearbox on e-bay but that gearbox turned out to bee more worn than the 1100 transmission i had in bike so then i searched more
on e-bay and found another complete transmission from a 96 1200 that has the longer shiftforks and had almost not been used so i bought that one too and installed it.
What is strange is how did i end up with 3 sets extra shiftforks :scratch_one-s_head: did i forget to install the shiftforks :biggrin: nope cant be that since the gearbox
has worked fine since it was installed 2018 and all of the 3 extra sets has short forks .Strange stuff !
Anyway i took a trip into post office today with one set of forks with the guidebar today and asked how much shipping to south africa was.They sat it on a scale and it was only 21 usd so i will send the set for free just pm me
Wow, it doesn't get any better than this.....
Quote from: Pat Conlon on March 04, 2023, 12:26:10 PM
Wow, it doesn't get any better than this.....
I once had a set of trigger coils for my fj1100 sent to me free, postage paid from a member on this site.
There was a FJ forum member (back in the Yahoo days) who was traveling cross country on a multi state tour, his generator stopped charging, and his battery failed stranding him in the middle of BFE....I think it was somewhere in Wyoming, a small town with 1 gas station & cafe *but* it had a public library. Jeff traced down the problem (burned stator windings, generator's toast) so he made some phone calls. The closest town like 80 miles away and the closest Yamaha dealer was in Casper, something like 130 miles away. He called the Casper Yamaha dealer and they said that he could get the part 'maybe' in a week or two.....Jeff walked over to the town library and used their public internet terminal to send out an SOS to our Yahoo FJ group. (This predated cell phones) Jon Cain responded. Jon went out to his garage, pulled a generator off his FJ and Fed Ex mailed it out to Jeff.....Jon told Jeff, "Keep the generator until you get home, then just send it back to me...". Jon Cain rocks....
If it were to happen today with our current FJ Owners Forum, RPM Robert or Randy would be responders.
That's how we roll....
Quote from: Pat Conlon on March 05, 2023, 05:00:51 PM
If it were to happen today with our current FJ Owners Forum, RPM Robert or Randy would be responders.
That's how we roll....
We've been doing it for years and are glad to help the FJOwners.com community. There have been many satisfying times this has occurred, but one of the most was when Ron broke down on his epic journey almost 10 years ago now.
You can read about on the seventh page of the journey:
Your dad only turns 80 once... (https://fjowners.com/index.php?topic=10252.90/)
Waiting for the sequel, although the FJ has been taken out of service due to wreck, but I can't find that post.
Randy - RPM
Don't forget the time you and Robert brought a new fuel pump to the WCR for me....
We are most fortunate to have RPM
Quote from: Pat Conlon on March 06, 2023, 01:44:31 PM
Don't forget the time you and Robert brought a new fuel pump to the WCR for me....
We are most fortunate to have RPM
Yeah, forgot about that one...
That was a learning lesson on eBay pumps of I recall it now.
Randy - RPM
Quote from: Old Rider on March 03, 2023, 03:37:01 PM
I checked with a route planner and if you live in cape Town south africa it is 14352 KM or 8886 Miles and estimated time to drive shortest route that
is thru trans sahara desert highway is 191 hours and 25 minutes. That is a little too long ride :biggrin:. But since im coming from the land of santa claus
i will go to the post office tomorow and check how much shipping is to South Africa.If it is not jaw dropping i will send the forks to you for free .
You can PM me your adress and name
I will happily pay any courier costs. Unfortunately our local postal services is on the verge of collapse and delivery of any overseas items can take up to six months to clear through customs. I did not want to put you through any trouble, but this is really a grand gesture. Fully appreciate your time.
Quote from: Old Rider on March 04, 2023, 08:21:19 AM
This morning i was down in the cellar and found the shiftforks.I was very surprised to find 3 sets of forks ?? .When i split the engine i wanted to change out the 1100 tranmission since the gears and dogs looked a little worn it worked fine, but since the cases was split i wanted to install a less worn gearbox. I first bought a complete 1200 gearbox on e-bay but that gearbox turned out to bee more worn than the 1100 transmission i had in bike so then i searched more
on e-bay and found another complete transmission from a 96 1200 that has the longer shiftforks and had almost not been used so i bought that one too and installed it.
What is strange is how did i end up with 3 sets extra shiftforks :scratch_one-s_head: did i forget to install the shiftforks :biggrin: nope cant be that since the gearbox
has worked fine since it was installed 2018 and all of the 3 extra sets has short forks .Strange stuff !
Anyway i took a trip into post office today with one set of forks with the guidebar today and asked how much shipping to south africa was.They sat it on a scale and it was only 21 usd so i will send the set for free just pm me
Agree with your route planning - what a trip it could be though :good2:
This is indeed very special and you have my heartfelt thanks.
Did send you a PM.
Quote from: Pat Conlon on March 05, 2023, 05:00:51 PM
There was a FJ forum member (back in the Yahoo days) who was traveling cross country on a multi state tour, his generator stopped charging, and his battery failed stranding him in the middle of BFE....I think it was somewhere in Wyoming, a small town with 1 gas station & cafe *but* it had a public library. Jeff traced down the problem (burned stator windings, generator's toast) so he made some phone calls. The closest town like 80 miles away and the closest Yamaha dealer was in Casper, something like 130 miles away. He called the Casper Yamaha dealer and they said that he could get the part 'maybe' in a week or two.....Jeff walked over to the town library and used their public internet terminal to send out an SOS to our Yahoo FJ group. (This predated cell phones) Jon Cain responded. Jon went out to his garage, pulled a generator off his FJ and Fed Ex mailed it out to Jeff.....Jon told Jeff, "Keep the generator until you get home, then just send it back to me...". Jon Cain rocks....
If it were to happen today with our current FJ Owners Forum, RPM Robert or Randy would be responders.
That's how we roll....
Absolutely amazing. Those values are scarce these days.
No problems im happy to help other fj riders since you PM me your adress i will post them today and lets hope the forks get to you fast !
Quote from: Urx on March 03, 2023, 01:52:59 PM
Your shift forks on the left look entirely shot to me and I wouldn't be building an engine back up with the ones on the right either unless it was life/death and no alternative available.....
If you are offered better forks for the price of postage then surely thats a sensible approach no?
Thanks for that. Yes, the process has progressed that far already with the kind-hearted Old Rider.
Forks posted
Did the shiftforks arrive ?