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Congratulations Ponyfool! Well done.

You're an inspiration to all of us who dread the thought of any kind of dealer maintenance!

 
I may have misspoke if I mentioned "special" tools as many of you already have most of these tools. After my house fire, I only had a basic set requiring me to go out and buy new ones. The ones I bought included two torque wrenches (foot/pound and inch/pound), large sockets (22mm-36mm), clutch tool, brake line bleeder, a spanner wrench (I think that's what it was called), socket allen wrenches, T-50 Torx bit, a hub puller (I think that's what it's called), and a few other things I'm not remembering right now. I did need a torque-angle wrench for the crankcase bolts, but I borrowed that from a friend.

There were no tools required that would have no other uses except the clutch tool. It is very specific. I've also never needed a T-50 Torx before, but now I have one. I've used hub pullers before, and had one before the fire, so that one isn't specific either.

Actual time in labor is a shot in the dark. I took a full day getting the engine ready to pull. This included removing the fairing, radiator, water pump, oil cooler, starter, air box, throttle bodies, etc. But a "full day" includes taking pictures, eating lunch, taking the kids to school, surfing the forum, listening to my wife, buying new tools (this was a huge time killer), etc. If I had to do it today, I could probably do the same thing in 1-2 hours.

I took about 4-5 hours actually taking the engine apart. But, this also included cleaning off bench space for all the parts, going to the store to buy parts, etc. Splitting the cases is actually not too difficult. The biggest challenge, and I was warned about it by a friend, is that the service manual will say something like, "Middle Gear Step 1, Crankcase - See Crankcase", but when you look at the Crankcase section, it discusses complete and total disassembly. So, much of my time was evaluating exactly what part of the crankcase disassembly was required, and what was not to accomplish my goal. I mean, if I followed the service manual, when I disassembled the crankcase, I would have had the crankshaft out too, and I didn't have to go there. Again, if I had to do it today, it would probably only take 1-2 hours.

Actually removing the tranny took maybe 30 minutes, half of which was just looking at it to see if it was as easy as it looked. Like I said, they've engineered this to be almost easy.

Reassembly of parts took me about an hour. I left the tranny in stock form, lined up all my new pieces (using part numbers to verify my visual comparison - see this thread to see what I mean) and then as I disassembled the stock tranny, I would reassemble it with the new parts.

Buttoning up the engine took me about 2-3 hours. Several times, I would do things without looking at the service manual because it was straightforward only to read the manual later and realize I didn't add grease or lube, etc where needed. That ate up some time.

I spent the better part of 4 hours trying to put the motor back in the bike by myself. While I now know it can be done, at the time, I wasn't willing to risk tilting the engine on my jack to get the final drive shaft over the lip to slide it in. After four hours, I was extremely frustrated and decided to go to a movie. My friend came over and we had the engine lined up in a matter of 3-4 minutes.

I then spent about 4 hours putting everything back on. I also completely tore off the front fairing when I started because I wanted to explore the limited space up front for future HID install. If I hadn't done that, putting everything back together would have taken an hour less I'm guessing.

So, Reader's Digest, a day to remove engine. A half day to split cases and ID parts. A half day to reassemble parts and a half day to put engine back in.

If I had to do it again, I'm guessing total actual time working on it would be about 10 hours.

But, here's the deal. If I did something wrong and I have a failure due to something I may have overlooked, I'm not going to do it again! I'll be too busy running in circles pulling out my hair screaming, "AAAAAAHHHHHHHHHHH"

I keep telling my wife that now that I've saved $2000 I should be able to spend that on something else, but she's better with money than I am and says not a chance :) But I did get more tools, so that's a bonus.

 
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I shall add my congratulations as well. I don't think, (I'm pretty sure, heck I wouldn't) attemp this type of repair. More good vibes that 'you' did. Glad it all came out well for you.

 
That's fantastic!! :yahoo:

'Course the downside is now EVERYBODY is going to be asking you questions regarding mech issues and whatnot...your PM box will constantly be full and you'll be asked by multiple FJR owners at NAFO.." How do you <mechanical question>...?" :rolleyes:

Congrats! See you at NAFO. :clapping:

 
Also, congrats. Don't know if I would attempt that myself or not. Probably have to call in some friends. What's this about a ride Sunday?

 
Congrats ona job well done and you really do have brass balls to do that job adn do it well... Go by and see your dealer and let him know that your are not held hostage by him. I t really freaks them out when someone pulls a jhob off like that. Way cool.

 
Very Cool!

Wish I could do something like this.

I'm pretty much limited to basic maintenance.

On my return from NAFO I will be due........

1. valve adjustment

2. cam chain inspection

3. TB sync

4. new plugs

5. new shoes

6. oil and filter change

:wacko:

 
Put a hundred miles on her today and I have to say, I think the tranny may have been fubar from the day I bought it. It is so smooth right now. I mean butter smooth. Shifting is effortless in every way. No clunking, no hesitation, just a smooth transition. It was NEVER like this before. Makes me think that maybe something wasn't quite right way early on and it just took a while to progress into the failure I had.

What do you think? Possible?

I am going to take the worn parts to the dealer so he can send them to Yamaha. If, as the service tech claims, Yamaha is interested in looking at the parts, they shouldn't care who took them out. I am not looking for any retroactive financial help, but I'll let them have the parts to inspect them so they can do their own eval.

 
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sooooooooo..................we're all getting Ipods, er what?
See my previous post. Here, I've emphasized the part that relates to your iPod giveaway.....

I keep telling my [SIZE=14pt]wife[/SIZE] that now that I've saved $2000 I should be able to spend that on something else, but she's better with money than I am and [SIZE=14pt]says not a chance[/SIZE]
 
Someone needs to create a "Master Feejer Mechanic" icon for PonyFool and others here that are able to successfully tackle truly difficult repairs such as this. If you can get an icon for crashing you should certainly get one for something like this!

GREAT job! Beyond impressed.

 
I would like to nominate PonyFool for the honorary Golden Wrench Award:

ponyfool.jpg


 
New gears and no clunking. Yamaha should consult you about tranny's

Nice job nothing better than good ole american know how.....

 
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