I'm definitely breaking the 2-week before Rally rule..........................

[Firehawk068]

Won't be the first time either..........






I just developed an issue with downshifting the transmission in any gear.

Upon further inspection, I found this (what looks like a piece of twisted barbed-wire) dangling loosely behind the clutch assembly.
I am thinking it is a broken spring of some sort. (Detent spring possibly?  )



Anyway, pulling the clutch this evening to see what I need. 

[aviationfred]

That appears to be the retainer wire between the first fiber and steel plates that many members have removed.

Number 8 on the diagram

http://www.partzilla.com/parts/search/Yamaha/Motorcycle/1990/FJ1200A/CLUTCH/parts.html


Fred

[fj1289]

Sounds like the shift mechanism not returning properly.

Thinking part number 8:



Let me know if you'd like to borrow an electric impact for the clutch hub nut (also have the socket).  I MAY also have the roller detent and heavy spring replacement part if you have trouble locating what you need in time for a comfortable completion before the rally.  -- on second thought, I've got the stock (used) parts on hand too --

Chris

[fj1289]

That appears to be the retainer wire between the first fiber and steel plates that many members have removed.

Number 8 on the diagram

http://www.partzilla.com/parts/search/Yamaha/Motorcycle/1990/FJ1200A/CLUTCH/parts.html


Fred

Funny we're talking two different parts on two different diagrams and they are both part # 8.

Fred - do those springs have a habit of getting out of the clutch basket?  I'd think it would be so thin that if it did get out and get into the shift mechanism it would get sheared or mangled before it would interfere with shifting.  I'm curious on this one!

Chris

[TexasDave]

Fred is correct. Other members have had this problem also. That retainer wire gets between clutch discs and does not allow the clutch to completely disengage thus the shifting problems. Inspect your discs for damage after disassembly.   Dave

[Firehawk068]

It is definitely not the "Judder Spring" that is deep inside the clutch basket.
That is intact, and the clutch works normally, like it is supposed to.
Upshifting works just fine. The problem is with downshifting.

I am hoping it is the detent lever spring. #8 in Chris's diagram, but I don't think it is.
Also, #5 is intact. I can see that is installed properly.

It appears to be a small piece of spring that is dangling from the (lever mechanism?) on the end of the shift-shaft #3

I've got shop-air in my garage, and any tools I think i might need.
I'll know more tonight when I pull the clutch out.

[the fan]

Look closely at #3 in the part diagram shown above.

There is a claw shaped part that engages the pins on the shift star. Most of these have a small spring that centers the 'claw' as you shift up and down. If this is broken or missing you would experience difficulty selecting a gear.

I don't remember if the FJ is sprung or not as I have never has to mess with one, but on my other Yamahas there is a spring.

[Firehawk068]

From what I can see without taking it apart yet (which isn't much), looking at a picture of the shift-shaft assembly, I am thinking that this is the spring that broke.



Chris, you wouldn't happen to have a spare shift-shaft (with spring intact) laying around would you?

[Mark Olson]

Call RPM now , they have used parts as well ... you could have it in your hands by sat.

[movenon]

Look on the bright side Alan. It is an easy fix (as fix's go) and better to find it now than during the rally when you would rather be riding. I know it is only money but it is a good time to install a "shift kit" from RPM while in the area.   Put your new toy to good use while you are waiting   
George

[Firehawk068]

It took me all of about 10 minutes to pull the clutch parts out.



The spring in question is the one I suspected.







From the pictures that Randy sent me, I have a better idea what it's supposed to look like.

It didn't break, but it somehow bent and unwound itself.
This is the reason why I still had up-shifts, but no down-shifts.

Anyway, I'm assuming when I pull the shift-shaft, all the oil that I just put in will pour out the shifter hole.
Now I need to pull the exhaust again, drain the oil into a clean container so I can re-use it, then pull the shift-shaft.

Off to the garage again. 

[FJmonkey]

Anyway, I'm assuming when I pull the shift-shaft, all the oil that I just put in will pour out the shifter hole.
Now I need to pull the exhaust again, drain the oil into a clean container so I can re-use it, then pull the shift-shaft.

Off to the garage again. 

Yep, the oil will leak out the open hole once you pull the shift shaft out. Good find, if you need to break a rally rule, then you did good. I can see that you found the thin retaining wire as well. Toss that part...

Maybe you need to get a clutch cover with a clear window from Fred. Then you can keep and eye on your clutch and catch issues early...

[Firehawk068]

Look on the bright side Alan. It is an easy fix (as fix's go) and better to find it now than during the rally when you would rather be riding. I know it is only money but it is a good time to install a "shift kit" from RPM while in the area.   Put your new toy to good use while you are waiting    
George

George, you are absolutely correct!

I am very thankful that it happened "right now"  instead of next Saturday (on our planned ride to Pikes peak), or putting a damper on my Central Rally fun in a few weeks.
The "Rally Gods" were definitely looking out for me on this one.

Good find, if you need to break a rally rule, then you did good.

I'd say so Mark!

[Firehawk068]

Look closely at #3 in the part diagram shown above.

There is a claw shaped part that engages the pins on the shift star. Most of these have a small spring that centers the 'claw' as you shift up and down. If this is broken or missing you would experience difficulty selecting a gear.

I don't remember if the FJ is sprung or not as I have never has to mess with one, but on my other Yamahas there is a spring.

You were spot-on here.
That is exactly what happened.

[FeralJuggernaut]

Isn't there a ball bearing at the end of the clutch actuator rod to keep an eye out for?   Or is that an 1100 feature?    Didn't see it on the parts explosion mat unless it is hiding in the shadows...