1991 FJ1200 - Starter clutch repair/replace

[Dino33L]

I needing some info on repairing or replacing the starter clutch on my 1991 FJ1200 - any thoughts or ideas? I trust the mechanic, who happens to be a family friend, but just wanted to get some feedback on this process.

[SkyFive]

Remove the engine and split the case. The FJ is a fairly simple design but there are alot of little things that need special attention. I would not tear into one without a service manual if I had never been into a FJ engine and even with a service manual a person has to be carefull.

If you do the starter clutch you might as well do the starter chain, it's that thing that makes all the noise because it's stretched. That means you will need to remove the cams, cylinder head and cylinder block, pistons/rods so you can remove the crankshaft to get the starter chain to the middle of the crank. It's a fun time...

[FJ111200]

Some of you might find this interesting. One of the guys on the XJR UK forum replaced the starter clutch and things by going through the sump and lower crankcase half without removing the cylinder head and cylinders.

http://www.yamahaxjrownersclub.com/phpBB3/viewtopic.php?f=39&t=29090&start=20

I've usually gone the traditional route, but this had me.

[andyb]

Can work on much of the bottom end/trans/starter clutch without pulling the cylinders/head off.  It's only about a dozen bolts more to get the head off though, if I didn't have a fairly fresh top end I'd spend the extra time and tear things totally down.

[Dino33L]

Thanks guys for the info and sorry for the delay in replying. I think I'm going to try going to 10w40. For most of the bikes life, I've been using 20w50 and I've been having this issue for quite a long time so I think this is a good try. If not, then I'll have to my mechanic friend do the starter clutch.