Yamaha Fazer 600 2002 Gearbox Help

[10kovako]

Hi,

I’m a bit stumped by an issue. This being that about 80% of the time to go upward from 2nd gear I have do repeatedly push the gear lever up until it goes in. Whilst I’m pushing it feels like I’m at the highest gear and it doesn’t allow me to go any higher. Can’t force it either. But after 5 tries it shifts. Revving it does nothing. It had this issue just with 3rd, but when I put a new clutch in the issue stopped altogether. 200 miles later, it’s started again. Also works immediately if I downshift then upshift again. Only from 2nd onwards but the worst is 2nd to 3rd.

What could it be? Hopefully doesn’t need a rebuild! Bike has 41,000 miles on it.

There is some free play in the gear lever shaft too don’t know if that is normal. (Side to side)
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[jaffa90]

A little free play side to side is ok, from what you say it`s a clutch problem so what oil is in the engine ? (hopefully it`s clutch friendly)???

[10kovako]

Thanks for the reply,

Yes it’s motorcycle oil, good stuff too. How could it be a clutch issue if it works when I go a gear down and then go up again?
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[Hong Kong Phooey]

If you tighten the clutch cable does that make any difference?
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[10kovako]

There are 3 places I can adjust the clutch, by the handle, in the middle, and by the clutch. Which ones(s) should I do?
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[chickenstrip]

There was a gearbox gremlin Yamaha had on a few bikes of this age. The R6 I think had it the worst, but Thundercats were also prone, and maybe the Fazer too. Even the Fazer 1000 had it on occasion, until Yamaha apparently did a fix in about 2003.

I can't remember the exact nature of the problem, perhaps others could confirm? I seem to remember the problem actually did need a strip-down to correct.
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[pompousporcup...]

the gear issue as far as i know on the older yamahas was that changing gear sloppily or at high revs from first to second would round the dogs on the second gear, meaning it would slip out of gear at high rpm.

R6s and Thundercats were apparently prone to it.. mine never did it but then i used to short shift into second and just rag second gear, rather than red lining first /shrug

the selector forks can also bend iirc making certain gears difficult to engage

[Pete.]

When you say that the lever feels like you're in top gear, is it that it won't actually move or that it moves but has no weight to it when it does?
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a.k.a 'Geri'

132.9mph off and walked away. Gear is good, gear is good, gear is very very good

[Kawasaki Jimbo]

I have a similar problem on a similar era Yamaha, although it's atypically not affecting 2nd gear. At the moment I've shut it in the garage and am in denial but I strongly suspect the forum is right, it'll be an engine out job to replace a bent shift fork. Check your gear shift linkages first. Fingers crossed!

https://www.bikechatforums.com/viewtopic.php?p=4633104&highlight=#4633104

[pompousporcup...]

[R1stu]

Could be the detent spring. Happend to my 02 r6. Its basiclyba spring inside the selector, that either comes off, or brakes. Gives all sorts of 2nd gear issue, has there us not the pressure to fully engage the shafts.

Simple job it seems, just needs selector cover off.
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[10kovako]

Sorry for the late reply! If it was a bent fork or something surely it wouldn’t go away for a little bit and come back?

Issue is just 2-3rd but is now creeping to 3-4. And when I pull the lever it feels like it’s in top gear, nowhere to go.

Also pops into neutral really easily. No clutch is needed.

Sometimes I have to do it twice till it goes in, sometimes just twice.
Getting carbs balanced on the 22nd so will ask him to take a look at it!
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[10kovako]

[10kovako]

[Pete.]

My money is also on the star wheel or detent. I'd be having a good look inside the clutch cover. Get a gasket and have the cover off.

It's the bits in this video here. The star shaped wheel behind the part you see moving is held in place by the sprung-loaded arm (the detent arm):

https://youtu.be/aiTAyP2C6X0
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a.k.a 'Geri'

132.9mph off and walked away. Gear is good, gear is good, gear is very very good

[trevor saxe-coburg-gotha]

There is a similar problem on some Kawasakis and Suzukis. The cure is very simple. Re-grease the selector. In the photo below, you can see the foot peg and the selector that the toe hooks under or presses.

https://www.picclickimg.com/d/l400/pict/183354318983_/Kawasaki-ZX9R-1998-1999-C1-C2-NINJA-Left-Gear.jpg

The parts that need cleaning and greasing are those. The foot rest part fits into the toe part - and unless the "female" part of the latter and the "male" part of the former are cleaned and greased it's not uncommon for gear selection to become extremely problematic.

See if the Yamaha has a similar type of selector arrangement.

I have read of several people replacing entire gear boxes on Kawasakis only to encounter the exact same problem! Eventually they suss out that it's just for want of a bit of cleaning and greasing of a simple, basic part.
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Mobylette Type 50 ---> Raleigh Grifter ---> Neval Minsk 125

[10kovako]

I’ll give the gear selector a good clean. Perhaps I should move the unit up/ down a notch or two?

Will ask my local garage to take a look at the spring see if anything is wrong with it!

Issue is still from 2-3rd. Still don’t understand why it went away and then came back!

Thank you though guys
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[trevor saxe-coburg-gotha]

Soz - I didn't attach the photo. I'll edit my post now.
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Mobylette Type 50 ---> Raleigh Grifter ---> Neval Minsk 125

[10kovako]

[trevor saxe-coburg-gotha]

It's the same w/ my bike - zx9r. Apart from faring panels, ebay has loads of spares. Inc. engines.
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"Life is a sexually transmitted disease and the mortality rate is one hundred percent."

Mobylette Type 50 ---> Raleigh Grifter ---> Neval Minsk 125