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?
Please press the Blue Button to appraise my Free! Efforts, Thank You!
Paul 'W' U.K.

Posted on Feb 18, 2009

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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.

Apr 04, 2012 | 2002 kawasaki VN 1500 Vulcan Classic

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I've got a 1988 Yamaha FZR1000 that jumps out of 2nd gear everytime when you open the throttle while 2nd gear is engaged. What will I have to do to get this fixed and does it mean I will have to split the...


The bike has a slightly bent shift fork. The slider gear that engages the second gear wheel is not fully engaging because of the bend. You must remove the engine from the frame and yes, the lower case half will need to split from the upper case half. You will not need to tear down the top end at all unless you choose to replace the rings. An observation; you are a brave man, a very good mechanic, or someone seeking adventure if you install new rings. There are a lot of parts and the cam chain re-assembly leaves no room for error. I would do it, but then again, I have 42 years of experience. Please rate my answer, Thanks!

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Aug 28, 2010 | 1988 Yamaha FZR 1000

1 Answer

My vn1500 jumps out of 2nd gear the manual says the engine has to come to bits to reach gear box any ideas


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

Jun 25, 2010 | 1999 kawasaki VN 1500 Vulcan Classic

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Rocket 111 second gear


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The bike jumps out of second back into neutral,


Since your engine has a horizontal split in the crankcase, the top end does not need to be torn down. Yes, a bent shift fork is likely to be the problem. Before going too far, first check the index wheel and spring on the end of the shift drum. The mechanism may be loose and/or the spring broken. If you are lucky, you may not need to split the case.
Please rate my answer. Thanks!
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Dec 19, 2009 | 1991 kawasaki ZZR 1100

3 Answers

Transmission seems to slip in second gear under load


time to replace the clutches or use fresh motorcycle oil

Nov 24, 2009 | 2002 Yamaha YZF-R1

1 Answer

Second gear jumps had trans replaced once help for bout 1000 mile doing it again what is causing it?


Your mechanic did you no favors. You have a bent shift fork. If the problem was present and was then good for 1000 miles the mechanic removed the fork, bent it back to nearly straight then put it all back together. If he had put in a new fork he would have charged you for it. If he said he could find no problem then how did the problem go away, magic? He probably didn't want to go to the trouble of finding you a new fork since the bike is 13 years old and the dealers wouldn't have the part. The problem will only get worse.

The entire engine comes apart > Head. cam chain, cylinder, flywheel electrics, clutch, oil pump, shifter, gears, shift drum and bad shift fork. This is best done by a dealer. If you try it yourself, be able to put 100 or so parts back together. Go to the site below and take a look in a parts manual. I couldn't find a free service manual for download. Yes, the link says Yamaha but you will change that when on the site.

http://www.babbittsonline.com/pages/parts/viewbybrand/1/Yamaha.aspx

To find parts, google " vintage kawasaki motorcycle parts "
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May 07, 2009 | 1996 kawasaki VN 1500 Vulcan Classic

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.

Apr 12, 2009 | 1996 kawasaki VN 800 Vulcan Classic

1 Answer

Jumps into second gear.


dont think its the clutch sounds like a bent shift fork, in first gear starting off the transmission has torque or pressure applied to the first gear set when you let the throttle off (no torque or pressure on tranny) it shifts by its self this is a sign of a bent shift fork hope this helps leave us a rate please

Jan 03, 2009 | 2001 Harley Davidson FXST Softail Standard

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