XJ550R engine removed!

It all started quite a while ago with the trans stuck in 3rd gear or higher. Everything external was where it should be and operational. So this is where I'm at now. One of my more pragmatic motorcycle wrenching friends suggested it was time to part it out. I just couldn't do it. After the joy of removing the engine, I could change my mind about that depending on what I encounter in the gearbox.
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Regardless of what you encounter, it's all fixable.

 

X2 - She's way too pretty to part out!

Just think, THIS is the POS i started with:



Have faith!! You can do it!

 

True. I happen to really like this bike. I've owned it 18 years. I might ride it more than the Connie if I get it sorted out.

 

Well for SURE then, can't give up on her now!

 

Here's a question: The drive sprocket had some play in it on the shaft. I'm thinking it shouldn't be that way?

 

There is some play on the drive sprocket shaft on my bikes too. I am thinking you might have a bent shift fork. Can you work the motor through the gears with the motor turned off? If you find you need internal parts, let me know. I probably have them.

 

I can shift through 3-4-5 engine on or off. A bent shift fork seems likely.

 

The 550s don't have the "crumbling primary chain guide" issue to worry about. And while a bent shifter fork is always possible, I think you're going to find the problem lies elsewhere.

The transmission WILL NOT be able to run through the whole pattern without turning the output shaft; it's the nature of sequential gearboxes.

I would more suspect a problem with the shifter "mousetrap" or shift drum; these items are located behind the clutch on the 550s. Broken springs in the mousetrap are common, and the shift drum retaining screw has been known to back out on 550s causing gear-selection issues.

I doubt you're going to end up having to split the cases; and I think you've jumped the gun a bit by pulling the motor. Short of splitting the cases, everything you need to look at beforehand could have been accessed with the motor still in the frame, and probably more easily.

 

Already did that Fitz. Believe me, I didn't want to pull the engine. No broken springs, no loose screws...

 

How about the shifter "crossover" shaft?

What makes you think it's a bent shift fork? You said you've had the bike 18 years; it seems to me that if a shifter fork was bent you would have to have been the one to bend it.

How many miles on it? Did the problem just suddenly occur one day?

I just think it's something else.

 

I swear it wasn't me! It was this guy:
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Yeah, came out of the blue. About 16K miles. I'll fill you in when I find the problem. Actually, the issue now is the elusive #24 lower bolt. I have two references, including the Yamaha manual, to remove it. The #"24" is clearly marked inside the lower casing but I see no bolts anywhere near it.

 

Ok, it was me. I think I know how it happened and I'll fess up to it when I find the problem. In the meantime, I can't find bolt #24 if indeed it does exist. Anyone else split the case on a 550 and have the answer?
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It has been years since I split the cases on one of these motors, but I think the bolt you are looking for might be hidden beneath the oil pump assembly. That would mean the clutch basket and oil pump would have to be removed. Send BigFitz a pm about it. He is our resident 550 genius. He probably knows for sure.

 

Thanks, zombie. I suspected that, but I don't thing the manual said to remove the oil pump. Of course the manual doesn't tell you everything unfortunately...

 

zombie, you were right. With a flashlight at the right angle I can see a corner of the bolt way up behind the oil pump. Cheeky.

 

In the Clymer manual it says to remove all external engine accessories. I guess the clutch and oil pump are considered external. Go figure. LOL I'm glad you were able to find it. I know how frustrating it can be.