2nd Gear Transmission Information - part number trivia

[capitanoinsano]

So I understand the fj1200 had some improvements in the transmission that helps prevent the 2nd gear popping out issue that can happen.  I know it happened more frequently on the FJ1100's unless you get the dogs/slots back cut between 2nd and 5th wheels.  But I read somewhere another improvement was made in 89.  So I checked the parts fiche and the gears are the same... But curiously one of the gear wheels (2nd or 5th don't remember) has a part number that starts with the typical 89 fj1200 part number not the 86/87 typical prefix.  I think it was 3CV for the 89/90 and 1TX for the 86/87 as typical prefixes.  So it makes me think the 89 may have had the new gear and the parts fiches may have been changed to that part for the 86/87 drawings/lists.  But I thought it would say "superseded" if yamaha did that.  But maybe since it was so long ago they didn't.  Or maybe 86/87 had the same 2nd/5th gear as 89, I don't know.  Does anyone know the answer to this trivia/design question?  Also are the 86/87 prone to 2nd gear issues, or is it a minor concern on a used 86/87 that seems to stay in 2nd gear now.

thanks.

[pdxfj]

The major issue with the earlier bikes were the shifting forks were somewhat weak.  Mis-shifting into 2nd caused the the 2nd/5th pair to bend.

Yamaha fixed it in the later bikes, and purchasing new gears and shifting forks fixes the issue.  A *few* have had the 2nd gear issue in the later model bikes, but I would imagine that it was more from abuse by a previous owner.

I am the third owner of my '87 and have no second gear issues.

[paulfj03]

it is my understanding that the shift forks were too weak in the earlier models (1100's), and eventually bent causing all the damage.....the forks were strengthened in the '86(?) and on to rectify the problem.... i also heard that it is ususlly around 50k kms or (40k miles) to 70k kms (50k miles) give or take, depending on how hard the bike was driven, for the damage to be noticeable...
The Ventures had the same gearbox/problem.  The shift forks have to be replaced and the gears undercut or replaced.


Has anyone here with a 1200 ever had the 2nd gear issue?

[Fred]

Has anyone here with a 1200 ever had the 2nd gear issue?

[/quote]

I did, I did!   My 86 had the problem when I bought it 13 years ago. My FJ enabler (friend who turned me on to the FJ) told me don't worry we can fix it and proceeded to talk the owner down t0 2 k. We replaced the shift forks and two gears. We had the  FJ enabler's step father undercut the gears for good measure then spent a Saturday putting them in. no trouble since.

[capitanoinsano]

I will check to see if fork part numbers are different.  But I am curious if Yamaha changed one of the gear wheels too in 89.  You can see the strange part number on any parts fiche of the 1886/1987, one of the gear wheels is a part number that shouldn't have existed then (3CV).  I bought an fj1100 about 10 years ago, owner lied about the source of jumping when accelerating hard in 2nd.  Since then moved to the 1200's

[andyb]

I believe the forks were strengthened (a second time, perhaps?) in 91.  My 90 has shorter forks than the later models (or it did, they're on the bench now..)

[Marsh White]

Has anyone here with a 1200 ever had the 2nd gear issue?

My 86 fj1200 has the 2nd gear problem...it had it when I got it and I haven't gotten around to fixing it yet.  That said - it has over 100K miles on it.  I just short shift 2nd when I ride it - and everything is fine.

[racerrad8]

I can not answer about the change of the gears, but the forks have been lengthened and strengthened. I have the updated forks in stock.

Randy - RPM

[pdxfj]

Forgot to mention the '86 I have sitting in my garage doesn't have the 2nd gear issue at roughly 55k miles.  It does have the heavy duty shift spring installed.

[paulfj03]

wow.     thanks guys....I had been told the design problem was rectified starting with the 86 1200's.  guess not!  guess thats what this forum is for, eh...
..my 86 is good...(so far)...

[capitanoinsano]

Well I think it was partially rectified, but more improvements were made in stages.  I looked at the Yamaha parts fiche and there were other parts rev'd since 86 with new numbers.  There was a spacer and another gear wheel.  I read somewhere that some changes were made in 89, then I found out here that forks were changed in 91.  I have not confirmed it, but I think gear wheels were changed some in 89 2nd or 5th (and 4th maybe).  The parts are superseded because they were compatible with no other changes.  But I know the fj1100's had a "glass" second gear, as did the 84 Venture Royales.

I nearly wrecked an fj1100 years ago because of the 2nd gear issue.  Was hauling a__ up an onramp with a pretty good lean and forgot I was in 2nd.  It jumped out of gear and back in, which caused a sudden increase of force at the rear wheel causing it to break traction and point me and the bike at a guard rail.  Got it straightened out somehow, don't really remember, then pulled over till I could start breathing normal.

[capitanoinsano]

One other comment.  The ultimate fix (as I understand it) is to cut the dogs/slots at an angle.  The shift forks get bent because of a "partial shift" and getting kicked hard by the gear if the gear pops out.  An angled dog slot engagement prevents this from happening period as the gears pull themselves together.

So if you do that, even the fj1100 transmission can hold up to torture.  Indexing the slots/dogs of the gears so they engage all at the same time helps too.

[Mark Olson]

I believe it is called undercuting the gear.

my 86 will be due for an upgrade soon as I am starting to miss my 2nd gear shift more often these days.

I let my brother in law ride it once and he hit false neutral every time he  went for 2nd.

from that point on I was screwed and had  to be real careful with the shift.

soon it will be time for transmission surgery.

[scapello]

I don't think the Yamaha fix worked well enough. I just had mine pop out and I have a '89 with 69k miles and heavy duty shift spring. It pops out right at about 6500 rpm and just scares the crap out of you/me. The only thing I can say is that mine only does it when going uphill and I have only let it do it a few times. Now I just shift up to third a bit faster, still enough torque and fun to be had.

[scapello]

I have to add that this only happens at full throttle all out acceleration.