91 shifter / peg mount help

[howiez69]

Hello all, new to the forum, I've owned my 91 FJ1200 since 1992. It was a new in the crate leftover model year, and i LOVE it. I'll probably never sell it. SO, i need your help with some maintenance.

This year when I dug it out of storage, everything was fine, rode it most of the summer without issue. Then one ride my shifter was 'spongy' from time to time. By the time I got home I realized the bolt it pivots on into the footpeg mount/frame area was loose. So I started to tear things down to fix it. Turns out it pulls completely out of the frame. There is nothing there to hold it. I pray there was a sleeve type screw/hex behind the frame going into the holes to mate with the threaded shaft. If it was a weld nut, I don't know how they'd weld it inside the tube. if it was 'inside' near the engine, on the outer face of the tube, I don't think the bolt would reach. Either way something is gone.

I went to my local Yamaha dealer to see if they could order the hardware and we cant find anything in the schematics. It's either integral to the frame and i'm screwed or it's in some secret place. I have not resorted to looking at wrecked ones yet, there is a salvage yard a few cities south east of me.

Does anyone have any knowledge or thoughts?

Thanks in advance!

[aviationfred]

If the threads on the shifter bolt are trashed, you can order a new one here. http://rpmracingca.com/proddetail.asp?prod=ShifterPivotBolt

As for the frame threads, I have heard of this before and know that it is repairable. I would contact Randy or Robert directly at RPM. Click on the RPM banner at the top of the page. It will take you to the RPM website.

Fred

[howiez69]

Thanks for the response!
No damage at all to the threads, its just as if something fell off (ok that's my hope!)

I'll try RPM!

[FJmonkey]

Sounds like the nut welded in the frame rail failed. The bad news is the rail needs to be removed. The good news is the engine can stay in place with the rail removed. A new nut or threaded bushing welded in will last another 20+ years.

[CutterBill]

Sorry for the late reply...

For some reason, Yamaha used very weak 8.8 bolts to hold the frame together. I've taken quite a few FJ's apart that had those bolts sheared in two. But McMaster-Carr (mcmaster.com) sells flanged-head 10.9 bolts that are much stronger; they don't break. (At least, I haven't seen it.) Install those bolts, use anti-seize on the threads (remember to use only 50-60% of the recommended torque) and you shouldn't have any future problems.
Bill

[Pat Conlon]

Yea Bill, those soft cradle bolts. Done a few myself.

I can't understand why Yamaha installed 8mm (soft) bolts, when the holes in the cradle allow a 10mm bolt....?

I just drilled out the 8mm threads with a 11/32" bit and tapped it with a 10x1.25 and used a off the shelf 10mm SS bolt from Ace Hardware. I found this fits the cradle much better than those sloppy 8 mm bolts.

[CutterBill]

I can't understand why Yamaha installed 8mm (soft) bolts, when the holes in the cradle allow a 10mm bolt....?

I'm guessing production tolerance. Easier to assemble if the lower frame tubes are just a tiny bit off-spec.  But I like your idea of drilling out and installing the larger 10mm.  Hmmm, where's my drill...?
Bill