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94 SUZUKI RF600R needs 2nd gear repaired. Is it possible to split the case without removing cylinders and heads?

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  • Suzuki Master
  • 44,864 Answers

Hi, Paul "ABSOLUTELY" no problemo 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 zero $ 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.
Topic replacing second gear Read 12467 times
Suzuki 1994 RF600R Service Manual
OEM parts for Suzuki

Posted on Jan 06, 2017

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6ya6ya
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Posted on Jan 02, 2017

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  • 3567 Answers

SOURCE: No second gear

Sounds like a bent shift fork to me. Not wanting to go into or between gears plus popping out of 2nd and making a knocking noise are classic symptoms.

Please rate this solution as a " FixYa " after the repair. Thanks!

Posted on Mar 24, 2009

  • 190 Answers

SOURCE: timing specs for 94 suzuki rf600r

shop manual page 16 and 22

Posted on Mar 27, 2009

rockitman187
  • 2559 Answers

SOURCE: I have a 1970 Yamaha XS650 that pops out of 1st gear.

No,You will need to split it to repair.

Posted on Jun 02, 2009

sisadsl
  • 1508 Answers

SOURCE: Hi. Suzuki rf600r 1993.

a 93 model is likely to need a chain and tensioner, if you undo the tensioner mounting bolts it should spring out 10-15mm

Posted on Mar 16, 2011

mxtras
  • 194 Answers

SOURCE: I have a 1982 Suzuki

Here's the easiest way:

Put the head bolts back on snug. Put the spark plug back in snug. Put the cylinder base nuts back on but leave them about 1/4" away from seat. Now give the kickstarter a swift hit down - you can do this by hand. Repeat until the cylinder pops up. Now, loosen the head nuts and repeat.

This is the easiest way to remove a cylinder.

Hope this helps.

Posted on Apr 29, 2011

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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.
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I don't know what has not been removed so pardon me if I suggest something already removed. Remove the cylinder, intake manifold, magneto, stator, sprocket and shift lever. A case splitter is highly recommended. They don't cost that much and it makes for a clean separation. The two positioning guides will tend to hamper separation as will the crankshaft and output shaft as they slide through the bearings. That's another reason for a case splitter. Now would be a good time for new crank and output shaft bearings and seals and a new shift shaft seal. I assume the reason for the teardown is either a bent shift fork or broken gear teeth. If replacing a gear with a broken tooth or two, also replace any gears the broken gear meshes with. If you don't, you will get to do the gear repair a second time very soon after the first ride. Whatever pressure broke the teeth on one gear was also present on the meshing gear. It may look good, but it isn't. Please take a moment to rate my answer. Thanks.
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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?


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Since the shifting was okay prior to splitting the cas, chances are one or both of the positioning pins fell out. If this happened, the cases are not lined up correctly.

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My banshee wont shift past 2 gear


You have a bent shift fork. The repair means taking the engine out of the frame then removing the top end, removing the flywheel and electrics, removing the clutch , shift mechanism and kick starter and a few other parts. THEN you are ready to split the gearbox to remove the gears and crankshaft and then the shift drum and bent shift fork. Next you get to put it all back together. This is a pretty big job for the home mechanic.

You will need an impact driver, flywheel puller, case splitter and torque wrench plus the normal screwdriver, pliers, etc.. Alternate to the special tools is taking it to the dealer and say "Fix it".
I normally tell people to take it to the shop just so they don't get into such an involved project.

Free service manual PDF download at > http://www.carlsalter.com/motorcycle-manuals.asp

Please rate this solution. Thanks!

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No second gear


Sounds like a bent shift fork to me. Not wanting to go into or between gears plus popping out of 2nd and making a knocking noise are classic symptoms.

Please rate this solution as a " FixYa " after the repair. Thanks!

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