Question about 1998 Yamaha YZF 600 R thunder cat

1 Answer

I threw the chain and it wedged between the case cover and front sprocket locking up the rear tire put it together and it started poping out of second gear... found two broken gear dogs replaced them still pops out of second gear split the case found broken gear dog and a bent shift fork replaced both everything else seemed to be ok... still pops out of second gear what else could it be

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  • toolboxtaxi
    toolboxtaxi Jan 13, 2013

    not a yamaha its a suzuki katanna 750f 1992



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  • Yamaha Master
  • 47,180 Answers

Hi, Toolboxtaxi for this scenario you will need your service/owners manual if you can't find the first and best tool you ever bought for your Yamaha, despair not, for a mere $10 you can download another one. For more information about your issue and valuable "FREE" downloads that you will need please click on the links below. Good luck and have a nice day.
YZF600R Forums View topic DIY Comprehensive 2nd Gear Fix lots of pictures
2nd gear problems
Yamaha YZF600 YZF600R 1994 2007 Service Repair Manual PDF Download Manuals...
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Yamaha YZF600RP Owner Manual

Posted on Aug 15, 2016


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Posted on Jan 02, 2017

  • 3567 Answers

SOURCE: Have broken the chain on a wrf 250 03 model and

I am unaware of any oil capillary by the sprocket. The only thing in that area not fully exposed to gear box oil is the left end of the shift drum. There wouldn't be enough friction on the drum to need any oil not already provided by the gear oil.

I would suggest the following > Drain the oil and then remove the sprocket and then thoroughly clean up the area around the sprocket and the break. Take the bike to a local welding shop. They should have a MIG or a TIG welder which will weld the casing. After the welding is done ,install a new oil seal on the output shaft.

The above suggestion is the low cost way to get by. The proper way is to replace the casing, preferably as a matched set of upper and lower case halves. If you get just the bottom, ( or top ), half you run a serious risk that the shafts may bind when bolted together. Replacing the lower casing is not all that big of a task. Replaceing the top casing is a pretty big job because the entire top end has to come off as does the crankshaft, clutch, gears and shafts, shift drum and electrical. Major project and NOT for the novice or the timid. You could Google ' motorcycle salvage yamaha ' and get the casing(s) or get the entire gearbox or the entire engine.

It's your decision how far to carry the repair. Personally, I would weld the box. It is a low cost and easy thing to try. Worst case is that you wind up replacing casings. Hey, the weld was worth a try!

Please rate this solution. Thanks!

Posted on Mar 27, 2009

  • 3567 Answers

SOURCE: 1977 ty 250. locks in gear. 1,2,3, or 4 th. and cannot be changed

You have nothing to loose. Try the adjustment. Try it a couple of times. Chances of a bent shift fork are 50/50. Drain the oil and remove the right side casing, Look at the shift mechanism. Is anything loose or a spring missing? Remove the shift shaft. Is the shaft bent?

Pleas rate this solution. Thanks!

Posted on Apr 05, 2009

  • 3567 Answers

SOURCE: yz 250 2008 possible 5th gear stripped, or shifting fork bent?

Do an oil change. If the gear were stripped there will be lots of metal particles in the oil. More than likely the fork is slightly bent such that the slider for fifth gear is just barely engaging. Put pressure on it by increased throttle and it pops out.

Go to the site below where you can see a parts diagram for your specific bike. You will select the actual brand, year, model, etc., once you go to the site. Part numbers and prices are also shown. You can order parts from this site. In the event no price is shown on a particular part, the part is not in stock.

Click on "Transmission"

Posted on Jun 01, 2009

  • 3567 Answers

SOURCE: 1st gear issues

How do I put this? Yes, you have a bent shift fork. And, yes, they can get bent in a fall, a dump, a drop or whatever terminology is used. The fork engages into a collar on a gear that slides left and right, (slider gear). Large "pins" called "dogs" are cast into the side of the gear. The dogs engage into holes in the side of the gear you are shifting into. Question: What happens if the bike drops on the clutch side and the shift lever is forced down, moving the slider gear to engage first gear even though the holes in the side of first gear are not lined up with the dogs on the slider gear? "You get a bent shift fork" is the correct answer. The force of the shifter lever moving the shift fork into the solid parts of first gear, (not lining up with the holes), is easily great enough to bend a fork. That pressure has got to go somewhere.

The repair means removal of the engine and a complete tear down of the engine/gearbox. The replacement of the bad fork is a given. But I suggest you do some preventative maintenance now, while the engine is apart anyway. Replace the sprocket shaft left bearing and seal, both crankshaft bearings and seals, shift shaft seal and the water pump seals. These are pretty low cost items and replacing them will mean you have pretty much rebuilt the engine. Have the dealer check the shift shaft to be sure it does not now have a bend in it.

Go to the site below where you can see a parts diagram for your specific bike. You will select the actual brand, year, model, etc., once you go to the site. Part numbers and prices are also shown. You can order parts from this site. In the event no price is shown on a particular part, the part is not in stock.

Go to this site and you can download a free PDF service manual. Most of the manuals are in English but some are not. There is no way to be sure without doing the download. You can always delete it if in a foreign language.

By the way, you can click on an experts name and see that persons profile.
Best wishes, tombones49 Please top rate this solution. Thanks!

Posted on Jun 07, 2009

  • 1978 Answers

SOURCE: Shift shaft is broken. Do I need to split the

Whether it is a four stroke or a two stroke, If you take the right crankcase cover off you should be able to access and replace the shift shaft. The mechanism is on the opposite side of the motor from the shift lever. You may have to remove the primary gear that contains the clutch pack to get the actual shift shaft assembly to slide out. The good news is you should not have to remove the engine from the frame or split the cases to do the job.

Posted on Apr 17, 2011

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