Question about Yamaha YZF-R6 Motorcycles

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Unable to select lower gears on downshift

Have a 2003 R6, 3,000 miles on clock, regularly serviced. On way to work this morning found was unable to downshift. With clutch fully depressed, gear selector moves all way down yet lower gear is not selected. I have no problem with going up the gears just seems downshifting is problematic. Any suggestions as to what may be causing this and how it may be repaired.

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The problem is simple and cheap to fix. There is a spring located behind the casing where the little splined shaft exits from the left side of the engine.(the one that is connected to the gear lever linkage.) One end brakes off and then you cant find the gears because the gear lever is not returning properly. You dont even have to drain the oil. Remove fairing. disconnect gear linkage. Remove casing. Make sure you find piece of broken spring and dont leave it in engine!!!! Replace spring and reassemble. Dont forget new gasket or use a quality sealant on the casing joint. (NOT THE BLUE RUBBISH CALLED INSTANT GASKET)...Happy motoring

Posted on Jul 22, 2009

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The bike has a bent shift fork or two. This is a MAJOR repair and best done by a knowing mechanic.
The motor comes out of the bike then turned upside down for removal of the bottom case. The clutch, shift shaft, flywheel, electrics, gears and gear shafts gotta come out so you can get to the bad fork. There's much more but the idea is that you are better off having the shop do the repair unless you have experience, are extremely mechanically inclined, and have the tools. The bad news is that a shop is going to charge around $1200 to $1500 for the repair. Some shop mechanics also repair bikes at home. If you find one, you can save $200 to $400 or so. Sorry to be the one to give you the bad news. The diagram below shows how a shift fork moves a slider gear left and right to engage different gears. A bent fork will not fully engage a gear.

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Posted on Jul 02, 2009

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