popping out of 2nd

[05fjrBluedevil]

Does anyone know or has it happened and yama fixing it under warranty?

At this point I am turning the bike into the shop Saturday, it appears that the oil seal leak they fixed is leaking again in the rear diff. so I will look for them to fix it again.

but the popping out of gear make me nervous if they will try not to cover it under warranty.

I was hoping to point out to them that they have covered others under warranty!

since the 06 ae moved to 5 up gear box I am almost certain they know it needed to be refined to remove the clunk, when moving to first and then second.

Any help would be greatly appreciated, it appears that this is at least a 1500.00 repair.

dropping motor out and splitting case to review the shifter forks etc.

has anyone else ever dropped the motor out of yours???

 

[Bearly Flying]

Yamaha has had problems with jumping out of 2 nd gear under acceleration since the FJ 1100 in 1984.

The engagement dogs on the gear cluster were straight cut. Hard shifting under load would wear the leading edges of the gear dogs.Popular fix back then was to undercut the dogs.

Don't know if the FJR has the same design, but it does sound suspious.

 

[GalaxyBlue]

since the 06 moved to 5 up gear box I am almost certain they know it needed to be refined to remove the clunk, when moving to first and then second.

huh... I didnt know that the '06 had a 5 up shift pattern... Both the "A" and "AE" are? I know that the AE is because i rode one. Seems weird to me though... :blink:

 

[escapefjrtist]

since the 06 moved to 5 up gear box I am almost certain they know it needed to be refined to remove the clunk, when moving to first and then second.

huh... I didnt know that the '06 had a 5 up shift pattern... Both the "A" and "AE" are? I know that the AE is because i rode one. Seems weird to me though... :blink:

It is just the AE that has the 5 up pattern, the A is a conventional pattern all of us know and love.

Haven't heard of hardly any problems with the FJR gearbox and there are many machines with substantial mileage on them. IMO popping out of second gear would be a result of some harsh treatment and rounded dogs. Good luck with a warranty repair.

--G

 

[madmike2]

I think Pegscraper had the problem on his '03. I don't remember if it was fixed under warranty or if he paid when he had other things done. IIRC, something was bent inside, not just the shift forks or the dogs rounded off. They're in the middle of moving, so I doubt he even has his email up right now.

 

[Rogue]

This CAN happen with bikes that sit on the dealers floor... People sit on it and play with the shifter (Saying Vroom, Vroom )and bend the shifting forks. The buyer ends up with bent shift forks and rounded dogs.

 

[05fjrBluedevil]

This CAN happen with bikes that sit on the dealers floor... People sit on it and play with the shifter (Saying Vroom, Vroom )and bend the shifting forks. The buyer ends up with bent shift forks and rounded dogs.

Well I wouldn't think that I abused the bike, always used the clutch to shift.

unless on the rare occaision when the shifter may have been bumped.

did recall numerous missed shifts when bike was new, and other times shifting to second from 3 only to have it go to neutral, then of course having to shift it to second.

so, all in all I think it should be taken care of by them ////Yamaha.

Hmm, makes me wonder if 07 will have the ae gear box set up. Seems netral at bottom and everythign else going up would make for a smoother shifting transmission. I road 3t's ae and the tramsmission seemed to shift silky smooth.

heck if they have had this issue with their bikes for 20 years, seems like they should pay for it if doing the right thing means anything in this world any longer.

oh well, if they do not cover it, it will be one heck of a winter project. because I am not paying someone else to do something like this especialissy if they jack the price by 4 times over parts.

guess I'll have to wait and see.

crossing fingers

 

[Geezer]

There were at least two people on the forum in the past year complaining about FJRs popping out of second under acceleration. I'm on dialup from home so I won't try to search for them today.

The first one was repaired under warranty, but the dealer first tried to blame the rider for it saying that abusive shifting would cause bent or worn parts.

The second owner said it may have been caused by him not shifting completely into gear. I don't remember if that one was resolved.

 

[05fjrBluedevil]

There were at least two people on the forum in the past year complaining about FJRs popping out of second under acceleration. I'm on dialup from home so I won't try to search for them today.

Well i know I have posted it earlier before going to EOM, second gear was sorely missed in the mountains.

The first one was repaired under warranty, but the dealer first tried to blame the rider for it saying that abusive shifting would cause bent or worn parts.

The second owner said it may have been caused by him not shifting completely into gear. I don't remember if that one was resolved.

Sure would love to know who had it repaired under warranty! I hope I do not need to bring it up but it would be nice to know and have it saved somewhere on this forum.

Maybe we need a thread home for warranty repairs done by yamaha and even a non warranty but good faith fixes.

 

[05fjrBluedevil]

There were at least two people on the forum in the past year complaining about FJRs popping out of second under acceleration. I'm on dialup from home so I won't try to search for them today.
The first one was repaired under warranty, but the dealer first tried to blame the rider for it saying that abusive shifting would cause bent or worn parts.

The second owner said it may have been caused by him not shifting completely into gear. I don't remember if that one was resolved.

Thanks found after searching for transmission.

 

[From Kapuskasing]

There were at least two people on the forum in the past year complaining about FJRs popping out of second under acceleration. I'm on dialup from home so I won't try to search for them today.

Well i know I have posted it earlier before going to EOM, second gear was sorely missed in the mountains.

The first one was repaired under warranty, but the dealer first tried to blame the rider for it saying that abusive shifting would cause bent or worn parts.

The second owner said it may have been caused by him not shifting completely into gear. I don't remember if that one was resolved.

Sure would love to know who had it repaired under warranty! I hope I do not need to bring it up but it would be nice to know and have it saved somewhere on this forum.

Maybe we need a thread home for warranty repairs done by yamaha and even a non warranty but good faith fixes.

I was one person who had second gear replaced under warranty - I had approximately 21,000 kms on the bike (13,000 miles). I have YES. My wrench told me it was caused by bent shift fork which could have been caused by one bad shift. Now, at 37,000 kms (23,000 miles), it is happening again! Parts are on order, and a guy from Yamaha wants to come and see the bike when it is apart. I'll post further when I have resolution.

Jim

 

[From Kapuskasing]

I just got word from my wrench that Yamaha was going to cover the second gear replacement this time, but only because I bought into YES. The next time I would be on my own.

I have a really hard time accepting this because I really do not abuse the bike: no wheelies, clutchless shifting etc. I have never had what I would call a bad shift, where the bike pops out of gear (false neutral?). I have never detected a shift where I would say that I thought "hmm, that felt weird". I have felt shifts where I thought the shift was clunky - I chalked that up to a chacteristic of the bike. I notice that the Yamaha manual recommends shifting at low revs and every mechanic I have spoken to suggest high revs e.g. 7k. I have noticed that the bike tends to shift smoother when shifting above 6k, but it is not consistent, and it's not always clunky when shifting at lower revs either.

Again, the wrench says that it only takes one or two "bad" shifts to bend the fork and start the downward spiral. Shouldn't the shift mechanism be able to withstand that?

It has been suggested that undercutting the gears would solve the problem and my wrench agrees with this, but said it will cost around $1500.

With the mileage I have and the extended warranty, I might just consider selling the bike in the spring, unless another alternative presents itself.

Anyone else having similar problems? Suggestions?

Jim

 

[ionbeam]

Really glad to hear that Yamaha is going to fix it (again) under warranty!

A lot of people have a lot of miles on their FJR with out any gear problems. A lot of people have given their FJR quite a pounding with nary a gear problems. To have it happen twice is ridiculous. S#it happens, bad parts, bad assembly, the mother of all bad shifts, any of these may account for one failure, however, if diagnosed and repaired correctly that should be it. There is a difference between throwing parts at a problem and solving the problem. Once your dealer gets your engine apart they need to find the root cause of the problem. As I mentioned in a PM to you, the problem could be fundamental to the engine case dimensions being incorrect, the main gear shaft could be bent, the shift drum may be damaged or machined incorrectly, etc. Don't let them put the engine back together until they find the real root cause. It might be time for your dealer to call the Yamaha regional tech and have them look into the problem.

With the mileage I have and the extended warranty, I might just consider selling the bike in the spring, unless another alternative presents itself.

May I suggest a trip to Yankee Siege and provide a load for it
Keep in touch, good luck with this repair!

 

[05fjrBluedevil]

Well I am still without my Bike, they order all gears and hopefully the shift drum as well.

Based on what I am seeing and reading it appears that as others have stated it only takes one botched shift, bad assembled at plant for this thing to break.

So 6+ weeks and still waiting, I could have had the bike back if I could take it anywhere I want and just let them bill YammY!

Oh well parts still 2+ weeks out, having the tps done as well.

If the bike does not run as I fel it should I'll take it back to them until it does.

have fun riding, looks like my season was and is over after returning from EOM as I had thought it would be.

 

[From Kapuskasing]

This was my second second gear replacement, so I'm now on my third second gear! There are at least 5 of us that have a shared experience with this, and I'm guessing that Yamaha finds that insignificant enough that their only reaction is to blame the rider.

When I get on my Aprilia Tuono, I am quickly reminded how a bike is supposed to shift - butter smooth - and even my wrench says that because I am riding this as my second bike, my shifting habits will improve so that the Yamaha won't have another failure.

Hmmm... Kawi Concours 1400?

Jim

 

[FJRMGM]

just wondering, do you guys with the second gear problem have the R1 shifter linkage mod installed?

Shifting is a lot smoother with it and I'm wondering if that would help?

 

[05fjrBluedevil]

just wondering, do you guys with the second gear problem have the R1 shifter linkage mod installed?
Shifting is a lot smoother with it and I'm wondering if that would help?

I do not, did not do any mods to the shifter, had I they would have probably blaimed the mod,

I actually pulled the heat blanket under the tank removed high way peg disconnected lights etc, I did not want them to try and find fault with anyhting I had done to the bike.

 

[tphfjr]

'03 with 105K miles - momentary skip in the drive train. It has happened a 4 or 5 times when accelerating on an uphill entrance onto the freeway - 2nd gear, under load at about 6-7K rpm.

 

[ionbeam]

Note the date of the opening post and the last post.

You can start a good read about second gear issues with ponyfool's post and links here.