FJR 33000 Mile Maintenance

At 33,000 miles, my 2006 FJR is due for some maintenance.

Most of this is routine maintenance and not warranty work.  Since this is a ‘farkled’ ld bike, I prefer to do as much of the work myself.  No sense in having someone worry about my GPS/Radar Detector/XM Radio and other add-on items.   Plus I get to know the work was done to my satisfaction.

On the agenda is:

…Done…
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Final Drive Swap
…Done…   My final drive started weeping again.  I have all the seals but even better I have a low mileage (2700 miles) rear end that I nabbed of eBay a while back.  I’ve done the swap, lubed up the spines and will replace the seals in my original unit.
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Head Bearing Upgrade/Replace with Tapered Set
…Done…

Special thanks to ‘Just Roy’ a forum member who makes an awesome head set socket and member ‘AllIn’ who loaned me the tools to remove the races and press in the new ones.

Ignition Switch Recall Work
…Done… 
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A local dealer was willing to provide the parts so I could do it myself.  Work performed in this service bulletin.  It’s a complete crock that Yamaha only gives these guys an hour service time.   It took me a good hour and a half and I already had the bike halfway apart.
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Fork Service
Oil on order, currently just a flush and refill with new fork oil but I’m jonesing for a suspension upgrade.
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… Done … Using Maxima 5wt Fork Oil.
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Valve Clearance Check/Adjust
I have a shim kit in stock and will do this in the next week or two.  This is the biggest item on the list and will take a good day for me to complete with coolant flush at the same time.  I should probably do plugs too but I did my initial set a little late and they looked great.
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… Done …

The 32K clearance check on my ’06 were:
#1 LI = 0.008, RI = 0.007, LE = 0.009, RE = 0.008
#2 LI = 0.006, RI = 0.006, LE = 0.009, RE = 0.008
#3 LI = 0.006, RI = 0.007, LE = 0.009. RE = 0.009
#4 LI = 0.007, RI = 0.007, LE = 0.009. RE = 0.009

All in spec though a couple of the intake valves were leaning towards the tighter side.   Proving once again that having the shims on hand means you won’t need to use them!

From FJR 33000 Mile mainteance

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Remove PAIR System and install the fancy block off plates.
Almost done, stripped a bolt removing one of the PAIR connectors.
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… Done …
HID Headlight upgrade.
I have the kit and with the front all apart I might as well do this too.

… Not sure I can use the kit that I have.  It’s really an auto-kit an the wires are simply too long for me to hide.
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Swap out BlueSeas fuse block for a smaller more compact and integrated unit.  (The FuzeBlock)
Have parts in stock, ready to do.
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Install Aux Plugs for heated gear
Installed, needs to be wired.
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Some photos of my work in progress:

 

Entire Album is here: http://picasaweb.google.com/mdisher/FJR33000MileMainteance#

Will update this post as things progress.

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