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

[Firehawk068]

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...       

There is! I see it sitting inside the (trans input) shaft.
I am going to just leave it right inside there where it is, and just eyeball that it's still there before I re-assemble everything back together.


I have to give a shout-out to Superman-Randy @ RPM.
He has his plate full of stuff at home, and took the time to answer my e-mails (very quickly), and return my phone call, and he has a used shaft on it's way with a new shaft seal already.
Super Awesome service from him, as always! 

[fj1289]

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?

Yes - I've got one.   I'll bring it by your work tomorrow around lunch time if that works for you

[Firehawk068]

Yes - I've got one.   I'll bring it by your work tomorrow around lunch time if that works for you

Chris, thank you.  Hang onto it for now.
I've got a shaft/arm assembly on it's way from Randy@RPM.
As quickly as he shipped it out, I'm guessing it will show up tomorrow.

I'm uncertain how common this issue is, but someone may need another one at some point.
Luckily it is an easy fix. 

[Goody]

Fantastic photo quality . 

[Goody]

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. 

great photo quality

[Firehawk068]

Fantastic photo quality . 

Thanks John.

Smartphone camera technology has come a long way. 
These were all taken with my iphone 6-plus.

[Firehawk068]

Spent some time in the garage today.

I didn't feel like pulling the chin-fairing, and the exhaust off again, so I just stood the bike over and dumped the oil out of the clutch housing.

Pulled the shift-shaft out.



I am not sure how the spring unclipped, and ended up on the wrong side of the tab?  
This is how it is supposed to look.



With the shaft/arm assembly out of the way, you can see the detent mechanism.



Since my FJ has a lot of miles on it (130,000 currently) the shaft has a lot of wear at the spot where it passes through the sprocket cover.



With the cover off, and the shaft pulled out, you can access the seal for the shift-shaft.





Took Randy's advice, and just popped it out with the end of a screwdriver.





This is as far as I got.  I'm expecting the shaft and seal to arrive tomorrow.
Then I'll re-assemble tomorrow evening.

[Firehawk068]

I received the package from Randy in my mailbox today. 
I can tell that the replacement used shaft that I received has a lot fewer miles on it.
There is only some light scuffing. Nowhere near the wear that my original one has on it.



New Roller Detent installed.



Popped the new shift-shaft seal in.



Sprayed a little white lithium grease on the replacement shaft, slid it into place, and locked it in with the washer and e-clip.





Got the left side all put back together.



As per the recommendation from Randy and a few others, I left this out of the clutch-pack when I re-assembled it.



Since I was re-using the fresh oil I had just changed, and having to dump it back in the engine from my clean drain pan, I threaded the end of a 2-liter pop bottle into the filler hole.
Trimmed it into a better funnel shape, and poured in the oil.
I didn't spill a drop! 



Nothing left to do but take her for a test-ride.
I have never had such smooth shifting with this bike before! Especially the down-shifts. (they were always a bit clunky since I've owned it)
It shifts like a totally different bike! 

Kudos again to Randy @RPM, for his expert advice, and super-fast service!
Excellent! 

[Urban_Legend]

This is great info. I have the feeling that it may end up on my to do list. I have the feeling the despite the quoted 35k miles on my motor, it may have quite a few more than that. And I have one of Randy's Detent springs to install.

Mark