Question about 1986 Yamaha FZ 600

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How would i go about replacing 2nd gear without splitting the engine case on my 87 yamaha fz600t motorcycle

Trying to replace the gear in the transmission (2nd only) without splitting the engine case or removing the engine from the frame of the bike? is it plausable to do this from the clutch side of the motor and still be road worthy?

Posted by Anonymous on


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Hi, Anonymous only in your dreams 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 $0 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
YZF600 Engine disassembly 2nd Gear Rebuild Full tear down
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Posted on Nov 07, 2016


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Posted on Jan 02, 2017

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SOURCE: '95 Yamaha YZ 125 clutch - stays in gear when clutch is pulled in

hey dude,, just thought id come in and give u some tips or 3,, i take it when u pull clutch lever in, and try and change gear it feels like your foot will snap b4 it goes in gear,, if that makes sense,, firstly mate,is to make sure the clutch cable slides freely ,easest way is to take cable off and just grab 1 end and make sure it isnt sticky,, if so dip one end of the cable in a bit of old oil ,,whilst holdin the other end ,pull and push the cable inner, this will **** up a bit of lubricant inside the cable ,, keep doin this each end till free to move, ,,next step if the cables ok,,, and may need help if u dont no,drain the oil out,,and as u r sat on the bike is to remove the clutch casing on the right hand side of the moter,where the bottom end of the cable goes,remove the casing being carefull not damage the gasket,,then u will see clutch plates and friction plates housed,, undo the 7 or 8 spring loaded bolts carefully take the first fibre plate out then metal friction plate then another fibre plate and so on,, wen u take the 1st plate out place that on the bench ,stacking each plate on top of one another, cause they have to go back in as they came out,,wen out,,u need a piece of wet n dry paper ,or fine emery,,and just wipe round both sides of the fibre plates taking the shine off them,as u put them back in,, put casing back on with a decent gasket,, oil back in cable on, make sure cable has no free play on the lever so wen u r about to pull lever in it bite straight away,, start her up, warm it up and try it,,any probs still il eat my shoe,, take care m8

Posted on Jan 10, 2009

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SOURCE: My Yamaha FZR 1000 Genesis clutch is leaking fluid

Sounds like you need to replace a gasket.

Posted on Apr 02, 2009

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SOURCE: battery replace tdm 850 yamaha

first remove seat then remove tank, unbolt the 2 nuts holding the fuel pump on then disconnect wiring and then wiring from battery remove 2 bolts holding in battery box and remove through whole where fuel pump was (take care with battery wiring).

Posted on Jul 07, 2009

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SOURCE: Clutch slipping (only is 2nd gear), on yzf600r

the problem is in the gearbox not in clutch

Posted on Jul 07, 2009

  • 440 Answers

SOURCE: Yamaha VStar 1100. Valve train noise after starter clutch repair.

The cam chain has stretched a bit making it look like its half a tooth out, the tensioner takes up the slack but makes the cam timing slightly out.
You could have timed the crank 280 degrees out
It should be timed on the T mark for one cylinder & on the I mark (if there is one) for the other.
The marks before the T mark are for ignition timing (firing marks)

Good Luck
Hope this helps.
(If it does then please mark this as 'useful')
Ride Safe

Posted on Jan 29, 2010

Testimonial: "Thanks! Have pulled right side cover off. Front cyl cam sprocket off by half tooth. Lower sprocket off by 5 or 6!! Starting from scratch."

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Split engine cases

Hi, Anonymous sorry you can't find the first and best tool you ever bought for your Yahama 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 visit the websites below. Good luck and have a nice day.
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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...

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.
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Jan 13, 2013 | 1998 Yamaha YZF 600 R thunder cat

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I have a 2009 yz250 with a good amount of time on it and i believe 2nd gear is out of it. it grinds n almost sounds like a chain slipping when i get on the gas and is like its in neutrel. what does it take...

Yes, the case will need to be split. The problem is likely to be a bent shift fork. A bent fork can stop the dogs on the slider gear from fully engaging in a gear. If the problem turns out to be a stripped gear, you need to replace BOTH the stripped gear AND the gear the bad gear meshes with. tombones49_273.gif

Sep 02, 2011 | 2003 Yamaha YZ 250

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Hi,my 1997 V-Max has got either a clutch or gear problem,when it goes into v-boost in 3rd gear it slips back to 2nd gear.

The coggs between the gears are worn, no simple fix. you just cant get on it very hard. And if you do it will strip out 2nd gear. In order to remove and replace the worn out gear you have to remove the engine from the bike, take off the upper half and split the case. and if youre going to go through all this trouble you might as well rebuild the whole engine. So I had a Vmax that 2nd and 3rd gear went out on me, (my heavy right hand and all) I could still ride it. the gas mpg was bad reving 1st till about 20 mph then skipping to 4th. But hey I put over 40k with it acting this way before I sold her and purchased anouther... Enjoy your beast and she will take good care of you

Feb 10, 2011 | 2000 Yamaha V-Max

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My 525s 2nd gear is whineing what is wrong

Thanks for contacting FixYa. I was reviewing some of the older un-answered questions trying to make sure your issue was resolved.

Usually 2nd gear whine is caused by bent shifting forks or dogs and the gear is wearing incorectly. The best solution is pulling the engine, splitting the cases and replacing the worn, bent, or broken parts.


Sep 12, 2010 | 2005 KTM EXC 525 Racing

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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!


Aug 28, 2010 | 1988 Yamaha FZR 1000

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Yamaha SR1 25 will not go into second Gear

The bike has a bent shift fork. The top end comes off then the side cases, clutch, starter, rotor, stator, etc... Then the case halves get split and you have access to the shift drum and forks. This is pretty major surgery on the engine and not reccomended for the novice mechanic. Some special tools are needed and if you don't have experience inside an engine, don't even think about doing the repair without a service manual. A dealer will probably charge $800 or so for the repair.

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To change out 2nd gear on a 2002 yzf 600r do i need to split the cases 100% or can i get to the transmitioin without having to dissasemble the engine?

Yes a 100% teardown is needed. There are two bolts on the case that are under the jugs (cylinders) that prevent the case from being separated. This is a full teardown, you will need to be very good at it or need a friend who is.

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