Trans/shifter issues

[Paul1965]

Last year while out enjoying the FJ one last time before winter, I came up on a turn that for whatever reason I wasn't prepared for. So I pulled in the clutch, hit the brake and aimed for a corn field. Unfortunately the transition from road to ditch was a lot rougher than I had hoped for, and I ended up dumping the bike at about 50 mph. I rolled 3 times as the FJ slid across the grass on its left side. Luckily this happened in front of a farm house and the folks that lived there came out and helped me and the bike up. I was fully geared up, and other than a slight left shoulder injury the only other thing hurt was my pride. The FJ didn't come out too bad either: it ripped the left lower fairing completely off and tore the shifter linkage apart. I was too sore to ride it back, so luckily got my friend Jason to come the 90 miles out and after a bit of rigging, he was able to ride it back for me.

He mentioned that it was very hard to find the gears on his way back, so now that it's finally warmed up I went out to the garage to see what was going on. He was correct, it goes into gear way too easily and neutral is almost impossible to find. I've already ordered a few parts I know I'll need, but I'm wondering what is making the shifting so sloppy? Could I have broken the torsion spring on the shift rod?

[Mark Olson]

possibly you did, what parts did you order?

you may want to get a shift detent kit from RPM .

with all the shift linkage off try to move the shift rod manually and feel for play and tightness. 

You may have damaged the shift forks or drum on impact. If the new linkage and detent kit does not fix it ,you will have to split the cases and inspect shift drum and clutch forks.

If you end up splitting the cases it would be a good time to replace 2nd gear and upgrade to stronger shift forks.  The early FJ's are known for weak forks and 2nd gear problems.

[simi_ed]

I'd look at the clutch, rather than the torsion spring.  Trouble find neutral sure sounds like a clutch thing. How about running in gear, on the center stand?  Skip the clutch, and see how well it works.  No load on the wheel, so no "need" for the clutch.

[Paul1965]

possibly you did, what parts did you order?

you may want to get a shift detent kit from RPM .

with all the shift linkage off try to move the shift rod manually and feel for play and tightness.  

You may have damaged the shift forks or drum on impact. If the new linkage and detent kit does not fix it ,you will have to split the cases and inspect shift drum and clutch forks.

If you end up splitting the cases it would be a good time to replace 2nd gear and upgrade to stronger shift forks.  The early FJ's are known for weak forks and 2nd gear problems.

I've picked up a used shifter linkage assembly and a used shifter rod just in case. But I'll bet the detent kit would solve my issue. I didn't ride it today but it feels like all the gears are there, there's just no resistance when moving between them. Do you think I really could have damaged something inside the trans though? When the bike went down it bent the linkage slightly and tore the washer and circlip off (18 & 19 on the exploded view) that holds the rear of the linkage on. The linkage itself never came off.

[Mark Olson]

possibly you did, what parts did you order?

you may want to get a shift detent kit from RPM .

with all the shift linkage off try to move the shift rod manually and feel for play and tightness.  

You may have damaged the shift forks or drum on impact. If the new linkage and detent kit does not fix it ,you will have to split the cases and inspect shift drum and clutch forks.

If you end up splitting the cases it would be a good time to replace 2nd gear and upgrade to stronger shift forks.  The early FJ's are known for weak forks and 2nd gear problems.

I've picked up a used shifter linkage assembly and a used shifter rod just in case. But I'll bet the detent kit would solve my issue. I didn't ride it today but it feels like all the gears are there, there's just no resistance when moving between them. Do you think I really could have damaged something inside the trans though? When the bike went down it bent the linkage slightly and tore the washer and circlip off (18 & 19 on the exploded view) that holds the rear of the linkage on. The linkage itself never came off.

with it that loose I would try the detent kit . The insides are probably ok if it shifts fine through the gears.

[Paul1965]

with it that loose I would try the detent kit . The insides are probably ok if it shifts fine through the gears.

In the interest of saving some coin, is #12 what I'd be after if I went with OE parts?

http://www.boats.net/parts/search/Yamaha/Motorcycle/1984/FJ1100L/SHIFT%20CAM-FORK/parts.html

[Mark Olson]

with it that loose I would try the detent kit . The insides are probably ok if it shifts fine through the gears.

In the interest of saving some coin, is #12 what I'd be after if I went with OE parts?

http://www.boats.net/parts/search/Yamaha/Motorcycle/1984/FJ1100L/SHIFT%20CAM-FORK/parts.html

yes, that is the spring . check the roller #13 when you have it apart. 
The reason I suggested the detent kit is that it comes with stronger parts and will give more positive shifts than stock . This will help with the missed shift /false nuetral problem and keep your shift forks from bending which causes 2nd gear to jump out under load in time. To install the shift kit you will be able to inspect your clutch as well .

I know it is expensive in regards to just a stock spring but it will save you from the trans problem for a while.

[Paul1965]

I know it is expensive in regards to just a stock spring but it will save you from the trans problem for a while.

Yeah, you're right. I'll order the kit from Randy.

Thank you very much for the help and extremely quick responses Mark!

[FJmonkey]

Yeah, you're right. I'll order the kit from Randy.

Thank you very much for the help and extremely quick responses Mark!

I did the roller bearing shift kit from RPM and would recommend it. My shifting is like butter now.

[Paul1965]

Unfortunately and much to my surprise, the damage is much worse than I thought.

[Flying Scotsman]

If you need help removing or installing your engine let me know.I always did it by myself and know that an extra set of hands would save a lot of time.

[Paul1965]

If you need help removing or installing your engine let me know.I always did it by myself and know that an extra set of hands would save a lot of time.

Thanks Scott, but I don't think I want to tackle this myself. I'm think I'll file an insurance claim and would guess they'll probably total the bike.

[Mark Olson]

wow , that is messed up.

[Paul1965]

I wonder if I couldn't pull the clutch out and clean things up enough to use some JB Weld or other similar product to patch it up. That's just where the shift rod passes thru right? There's no torque or pressure issues to worry about is there?

[Dads_FJ]

I wonder if I couldn't pull the clutch out and clean things up enough to use some JB Weld or other similar product to patch it up. That's just where the shift rod passes thru right? There's no torque or pressure issues to worry about is there?

From what I can tell that pin is what the spring pushes against for the 'detent' and the purpose would be to return the shift lever to 'home position' if it were?  If I'm correct I'd see if it could be TIG-welded.