Question about 1996 Yamaha YZF 600 R thunder cat

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Does the engine have to be split between cylinders to replace second gear ? it keeps jumping out of gear and putting its self back in.

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Hi,
The gearbox's on nearly all in line multiple cylindered machines lie in the base crankcase and is all locked together with the top crankcase.
So unfortunately a separation of these cases has to be made to access the layshafts & extract the gears, I somehow think that it is the Baulk ring that will be the problem not the gear itself?
Hope this clarifies things a little?
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Posted on Feb 18, 2009

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My 2002 ford focus only goes into gear when car is off. Put it into gear and turn car on and it jumps out of gear. Then you can't get it back into gear again unless you turn car off. Car will


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2002 Vulcan will not stay in second gear


It sounds like a bad shift fork, shift drum or worn dogs on the gear itself. Very labor intensive. have remove engine from the frame and split the cases.

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Consider a shock absorber. The first push it can make, then it does not refill the void fast enough to make the second push. Because of engine reving, you jump from 1 to 2 quicker than 2 to 3 gear. The slave cylinder does not have enough time to refresh. Maybe look at the weight of the oil in the slave cylinder.

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CORRECT. COMPLETE ENGINE DISASSEMBLY BECAUSE CRANKCASES SPLIT HORIZONTALLY CYLINDER'S MUST COME OFF FIRST. BIG BUCKS

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1 Answer

Keeps jumping out of second gear. Tore down the


The gears ARE probably fine. The problem is a slightly bent shift fork. Since the engine is apart I would STRONGLY advise you replace the shift fork. If nothing else it is cheap insurance that you won't have to replace it four weeks later because it won't shift into first. I have replaced shift forks that looked perfectly good but were bent such the you couldn't get into 2nd gear. Looks can be deceiving.

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