Question about 1988 Yamaha FZR 1000

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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 engine? Also If I have to, will I need to replace the piston rings?

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  • njmeintjes Aug 29, 2010

    Tom, thanks so much for your prompt response. This was indeed very helpful. I was wondering how do you know when the problem lies with the shift fork and when it's the gear itself? It sounds like this is quite a common problem on the FZR's. I suppose you've seen this many times before. I'm really glad to hear that the top end can be left alone. How difficult would you rate the procedure of replacing the shift fork? Also, would I need to replace it or can it be fixed by an engineering company?

  • njmeintjes Aug 29, 2010

    Tom, thanx so much for the great solution. I wondered, how do you know when the problem lies with the shift fork and when would it be the gear itself? Would I need to replace the shift fork or can a engineering company fix it? How difficult would you rate this procedure? Not sure if I should be brave here... I suppose it would be a good idea to get a Haynes workshop manual for this procedure.

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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!

I've got a 1988 Yamaha - 56999e1.gif

Posted on Aug 28, 2010

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  • tombones Aug 29, 2010

    Trying to straighten a bent fork is useless. The weakened fork would just bend more easily due to metal fatigue and the cost of a machine shop repair would be more than the cost of a new fork. The dogs on the slider gear "could" get worn but they will ( rarely ) break off the body of the slider gear. There is a 99% likelyhood the problem is the fork. When replacing the fork, also check the shift fork shaft. Roll it on a flat surface to be sure it is not slightly bent. It doesn't happen often but I have seen it happen due to a busted gear tooth. A factory manual is better than Haynes or Chilton if you can find one. Bent shift forks are a common problem in all brands of bikes.

    I wouldn't try the repair without a manual. The repair is easy enough for me because I have the tools and experiance. I seldom recomend a novice do a transmission or major engine repair. I have had too many engines brought to me in a basket when the owner got in over his head.

  • tombones Aug 29, 2010

    Trying to straighten a bent fork is useless. The weakened fork would just bend more easily due to metal fatigue and the cost of a machine shop repair would be more than the cost of a new fork. The dogs on the slider gear "could" get worn but they will ( rarely ) break off the body of the slider gear. There is a 99% likelyhood the problem is the fork. When replacing the fork, also check the shift fork shaft. Roll it on a flat surface to be sure it is not slightly bent. It doesn't happen often but I have seen it happen due to a busted gear tooth. A factory manual is better than Haynes or Chilton if you can find one. Bent shift forks are a common problem in all brands of bikes.

    I wouldn't try the repair without a manual. The repair is easy enough for me because I have the tools and experiance. I seldom recomend a novice do a transmission or major engine repair. I have had too many engines brought to me in a basket when the owner got in over his head.

  • tombones Aug 29, 2010

    Trying to straighten a bent fork is useless. The weakened fork would just bend more easily due to metal fatigue and the cost of a machine shop repair would be more than the cost of a new fork. The dogs on the slider gear "could" get worn but they will ( rarely ) break off the body of the slider gear. There is a 99% likelyhood the problem is the fork. When replacing the fork, also check the shift fork shaft. Roll it on a flat surface to be sure it is not slightly bent. It doesn't happen often but I have seen it happen due to a busted gear tooth. A factory manual is better than Haynes or Chilton if you can find one. Bent shift forks are a common problem in all brands of bikes.

    I wouldn't try the repair without a manual. The repair is easy enough for me because I have the tools and experiance. I seldom recomend a novice do a transmission or major engine repair. I have had too many engines brought to me in a basket when the owner got in over his head.

  • tombones Aug 30, 2010

    Trying to straighten a bent fork is useless. The weakened fork would just bend more easily due to metal fatigue and the cost of a machine shop repair would be more than the cost of a new fork. The dogs on the slider gear "could" get worn but they will ( rarely ) break off the body of the slider gear. There is a 99% likelyhood the problem is the fork. When replacing the fork, also check the shift fork shaft. Roll it on a flat surface to be sure it is not slightly bent. It doesn't happen often but I have seen it happen due to a busted gear tooth. A factory manual is better than Haynes or Chilton if you can find one. Bent shift forks are a common problem in all brands of bikes.

    I wouldn't try the repair without a manual. The repair is easy enough for me because I have the tools and experiance. I seldom recomend a novice do a transmission or major engine repair. I have had too many engines brought to me in a basket when the owner got in over his head.

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Pulled a D reg one of these apart a couple of years ago and had to take off the top end to split the bottom as mr yamaha in his wisdom had hidden bolts between the barrels that hold the crankcase together.
check your manual well - also the earlier models had some gears presed onto the mainshafts not splined - again worth checking

Posted on Aug 31, 2010

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