1993 FJ1200 from Minnesota

[1tinindian]

As promised, the right hand shifter mod, in pictures.
I took a lot from all angles, but if there is something else you'd like to see, that I haven't captured, just ask.

Leon

The stock, left side.


The right side shifter.


Both are operational at the same time. One doesn't need to be remove for the other one to work as they operate off the same shift shaft, just this one has been extended through the clutch cover.







You can see in this picture how the rear brake lever has been heated up and repositioned to make room for your foot to operate the new shifter.

[squidley63]

Really appreciate the pictures. I've been kicking around the idea since my accident of switching the shifter to the other side. I miss being able to smoothly shift a bike and can't stand the idea of an air shifter setup. Good thing the gearing and the motor on the fj don't require a bunch of shifting at the pace I ride on the street.

[bigguy136]

I'm the guy who made the shifter (and rode a few miles on the FJ), I used original FJ parts for the shifter and pivot but the piece that bolts onto the shift shaft came from any year FZR 400 or 600. I used it because it was a stamped plate making the cutting/ welding easier than using a FJ component. To keep the throw the same, I added a .250" sq stock for a spacer. In the picture below, you will see two welds just below the shift shaft. The .250" spacer is between the welds.
The shift shaft is the stock FJ shaft but I welded a second partial shaft onto the original so I had a splined shaft coming out both sides.
The cover was modified by first removing the original shaft, putting in a transfer punch into the shift shaft location, putting the clutch cover back on and hitting the other end of the punch. That made a center punch mark inside the cover. From there, I put the cover in a mill, indicated in the center punch mark and used a boring head to put the hole in the cover. I made an aluminum plug that pressed into the hole I made and used JB Weld to hold in place. almost 200,000 miles and still holding great. I also machined it so it took OEM FJ shift shaft seals and added a needle bearing for smoother shifting.
I have the transfer punch that someone in WI asked for. I will be mailing it to him/ her and from there, maybe they can continue to ship the transfer punch to who needs it.
Kevin

[Steve_in_Florida]

My hat's off to you, Kevin.

Your (former) bike looks almost new. You took care of it, I can tell.

Pretty ingenious workmanship on the "dual" shifter setup. You're probably pretty handy to have around!

Cheers to you, and I'm happy your bike went to a good home.

Steve

[1tinindian]

Kevin, so nice to see you come in and share your mod in detail.
Your work is very impressive. I'm sure others here could benefit from your back ground and years of hands on experience with motorcycles in general and Yamahas specifically.

Leon

[56 CHEVY]

Nice job Kevin! Very well executed.

[1tinindian]

I finally got some free time tonight and pulled the right hand shift parts out and boxed up to send to giantkiller.

Here are a few interesting pictures while I was at it.

The modified shift shaft compared to a stock one.






The inside of the clutch cover.





The clutch.



With over 182K miles, the dreaded wire spring is still intact.





Clutch plate wear on the basket.





The wire will not be going back in!



The modified parts heading to their new owner.
Paying it forward.

I still need to spec out the clutch frictions and plates and spring, in order to determine any further course needed.

If it can be determined by the photos, can I here your opinions on the usable condition of the clutch basket.?? Thanks.



Leon

[giantkiller]

Thanks Leon. I couldn't wait to tell my brother, that he could now get an fj. I was going to put the parts on my bike the next time I went to OKC. And say go take it for a ride. But that wouldn't be until next year. So I called and told him. He got all excited. And said he remembered riding my first fj. Back in 86. He said he remembered looking down at the speedo and reading 145 mph.and thinking "I gotta get one of these. And now 27 years later he can.

[1tinindian]

Thanks Leon. I couldn't wait to tell my brother, that he could now get an fj. I was going to put the parts on my bike the next time I went to OKC. And say go take it for a ride. But that wouldn't be until next year. So I called and told him. He got all excited. And said he remembered riding my first fj. Back in 86. He said he remembered looking down at the speedo and reading 145 mph.and thinking "I gotta get one of these. And now 27 years later he can.

I think that is so awesome, that these parts will be going to the "right" person, that can make good use of them.

This community is great!

Leon

[squidley63]

I gotta say its awesome that those parts can get someone back on a bike. Very ingenious and well executed 2 nd shifter.

[Dads_FJ]

Thanks Leon. I couldn't wait to tell my brother, that he could now get an fj. I was going to put the parts on my bike the next time I went to OKC. And say go take it for a ride. But that wouldn't be until next year. So I called and told him. He got all excited. And said he remembered riding my first fj. Back in 86. He said he remembered looking down at the speedo and reading 145 mph.and thinking "I gotta get one of these. And now 27 years later he can.

Is he near Rochester mn?  http://rmn.craigslist.org/mcy/3969531831.html

[movenon]

Thanks Leon. I couldn't wait to tell my brother, that he could now get an fj. I was going to put the parts on my bike the next time I went to OKC. And say go take it for a ride. But that wouldn't be until next year. So I called and told him. He got all excited. And said he remembered riding my first fj. Back in 86. He said he remembered looking down at the speedo and reading 145 mph.and thinking "I gotta get one of these. And now 27 years later he can.

Is he near Rochester mn?  http://rmn.craigslist.org/mcy/3969531831.html

Nice looking bike and a pretty good price.... I just live in the wrong part of the country....
George

[RichBaker]

Clutch basket looks fine, I've seen some on MX bikes that were grooved 1/4" deep. We just filed it down and kept running it.....   
Can you even feel indents there?

[bigguy136]

Nice to finally see what the clutch looked like. I was going to pull the clutch just to see it but never did. Glad you posted some photos.
I kept the wire in the clutch as it was to add a slight drag if shifting when you weren't moving. The clutch did have a little bit of slip when at full throttle and at the torque peak but otherwise it felt good.
I think I have a few complete clutch baskets, pressure plates ect at my shop. One of these days I should start opening up some of my boxes...
Thanks again for the photos and bringing back the memories of when I did the shifter.

[racerrad8]

I still need to spec out the clutch frictions and plates and spring, in order to determine any further course needed.

If it can be determined by the photos, can I here your opinions on the usable condition of the clutch basket.??

Thanks, Leon

Leon, I am sorry I missed this last night and all of today, I thought it was another bike sale post...but then Rich said clutch basket.

Good to go on the basket & clutch boss. You need to look at the frictions and steels and then make a decision on which option you want to choose for better clutch engagement.

The options are well listed throughout the annals of this forum. I am here to help you will any option you choose.

Randy - RPM