YZF600 Engine disassembly 2nd Gear Rebuild, Full tear down.

Рет қаралды 183,980

12 жыл бұрын

1996 yzf600RHC basic engine disassembly for 2nd gear replacment. show complete engine through splitng the cases and investigating gear damage. to 2nd and 6th gear wheels. not a replacemen for service manual but will show you what you are in for, in donig the job yourself. replacement, reassembly, and engine install vids to follow.

Пікірлер: 125

@whoblowsthere002 11 жыл бұрын

If you look at your drum track where Fork "L" rides, at the very peak of the vein where it passes over the hump you will notice a slight shine/peened/rounded edge it is VERY intricate to notice but I bet you will see it! The fork nub rounds off as well so its a combination of wear, the drum MUST be replaced for a proper fix!! Thanks home dog, thanks for taking your time to compose such a piece! Two beers for you!

@gneissguy4342 3 жыл бұрын

Damn, an oldie but a goodie. I just bought a 1995 FZR600 that I'm going to rebuild. This is a really nice resource. Thanks for posting.....8 years ago :)

@chrisburnsed6349 5 жыл бұрын

Thanks for making this!!!! There isn’t shit on KZfaq that goes this in-depth.

@flyslow2096 8 жыл бұрын

love all the detail

@OUBrad 7 жыл бұрын

Thank you for this video. Having the same issue with my 03 600r. Have my motor out and almost taken apart. Used this video as reference several times. Hopefully just the shift fork for 2nd gear.

@manuelvarela6905 10 жыл бұрын

Cool shit. Good work. Thanks for a video like this. Anything motorcycle is good.

@ricardopedrosilva4152 10 жыл бұрын

Hi! Thanks for the excellent videos that are better than reading some manuals. The videos did I managed to do everything at home. P. S. Sorry for my English

@abuelofm5 10 жыл бұрын

Thanks 4 the vid. Very very helpful.

@DieConstant 9 жыл бұрын

Thanks for showing me where that sneaky bolt 19 is to split the cases.

@guyblin 8 жыл бұрын

LoL went through 2nd gear on my Thundercats allll the time. In the end just used to ride without it. Used to hook up with a mate on his Thunderace... he had no 6th gear... but we still rode rings round the shiney boys with all their gear and no idea ;) Shame - I loved my Yammys, but shite gearboxes... especially after feeling that Suzuki love!

@whoblowsthere002 11 жыл бұрын

Thanks man, just put an hour into it this morning between auto jobs, about halfway to engine removal, I downloaded a PDF so i'll let you know if I need any more advice!

@studiosL-nc8bu 8 жыл бұрын

excellent vid m8, thanks a million xxxxxxxxxxxxxxxxx

@mydan78699 12 жыл бұрын

Wow thanks for the fast reply, im using Shell Advanced ultra FS which is not evergy conserving so at least i cant point to that, what i do know is i will keep my thundercat till i can no longer keep it running meaning one day ill be needing this video, thanks a lot in advance =]

@singlestallgarage 12 жыл бұрын

no worries your welcome. I am just pretty much always at the computer for work stuff. help how I can.

@singlestallgarage 11 жыл бұрын

ebay has fsms for 10bucks, first thing to check (internally) would be the shift shaft as it is likely bent. look at my section videos, find the clutch removal part, and you will see what is required to do it. in that section i point out the shift shaft what goes wong. stuck in gear or tuff shifting is usually because of the bent tab. however it got bent front internal damage kicking out the shifter causing damage. a shaft will likely get you going, but rebuild is likey in your future.

@coastalplayer 3 жыл бұрын

like #892 appreciate your detail on this

@nicnadu0515 3 ай бұрын

I paid 200$ for a 2002 yzf600 and now I got the engine running great but it’s on a table without a bike lol

@Sdavids907 10 жыл бұрын

Sweet vid, I'm getting a 05 r6 soon. First bike and was curious to how the upper and lower end work on a smaller engine

@singlestallgarage 12 жыл бұрын

if you are not popping out of gear or having to great of difficultly shifting into gear then the shift kit may help you out in better shifts. it is a worth while upgrade to have regaurdless. BUT once the damage is done (even if it is slight as it probably is with yours) your future will have a rebuild in it. but untill its broke broke, keep riding it, says me. i limped along for several thousand miles and couple shift shafts just to get bye, untill i was able to do a proper fix.

@singlestallgarage 11 жыл бұрын

also, for me, for some reason my shfit fork, wouldnt sit agains the gear properly causing the funny wear pattern, i attributed this to the drum. now i havent pulled this apart to look at it mind you, so i cant say how much wear there is currently. but it has been working a dream, with no problems. so i am happy i did it all, since it was a success. but yea i saw no damage to my drum visually, so odds are in your favor its fine but its a lot of work to take it apart again

@chrisburnsed6349 5 жыл бұрын

Acetone with a scotchbrite pad works best for carbon and old gasket material removal. Does not hurt aluminum.

@whoblowsthere002 11 жыл бұрын

Thanks! Yeah mrcycles.com has me sitting a hefty $380 with headgasket and some random cvowling fasteners. Im very pleased as the numbers at the cycle shop came to almost DOUBLE that. Also, before I went to the cycle shop I took the drum out to really look at it. They DO WEAR along with an improperly operating fork, Since shifting to 2nd is a hefty chore under full load, its normal for the drum to wear along with the fork causing the issue eventually.

@MrRaminolo 11 жыл бұрын

с удовольствием посмотрел, спасибо!

@Adam-kb2mn 10 жыл бұрын

Thanks for your video.like many thundercat owners its only a matter of time before I have to do this.Good bike apart from a crap gearbox

@davidervin4853 9 жыл бұрын

Glen Hill replace with a 2003 gearbox it will fit and resolve the dreaded 2nd gear problem

@cameronadam5805 8 жыл бұрын

+david ervin could i do something like that with a 1988 would much rather put a newer gear box in rather than rebuild it

@thatcutndude1 11 жыл бұрын

i just check it again and im missing my spacer for the shift shaft....and im thinking this causing my problem cause ther is to much play on the shaft and i dont think itz engaging...looking 4 a spacer now...thanks 4 the video.....

@MrFr3tless 10 жыл бұрын

I've got this job to do soon :(

@singlestallgarage 11 жыл бұрын

yes most likely the fork is worn/bent. also because of it not egauging all the way the dogs on the 2wheels(what we call gears in USA, 2nd and 6th) so it wont mesh nice or stay in place. it is also possible the groove on the shift drum is worn too. also if this has been going on while or the shift lever gets thrown out, the tab on the shift shaft might be bad too. yes the motor HAS to come come out and be opened up to remove ANY transmission gears. no way around it.

@samualiam9981 9 жыл бұрын

Now I have a better idea why my transmission clunks into first. Thanks friend.

@davidervin4853 9 жыл бұрын

Samual Iam people over estimating this engine. ohh i got a fancy race bike i dont need to pull in my clutch al lthe way with every shift. YES you do. that causes most 2nd gear problems with these earlier year r6's

@samualiam9981 9 жыл бұрын

***** I figured that was the cause of it. The guy who owned it before me seemed like he was hiding something. Oh well.

@davidervin4853 9 жыл бұрын

Samual Iam sorry to hear that people always fucking everyone over in the used bike/parts world....

@camarov5456 5 ай бұрын

@@davidervin4853So clutchless shifting is not a good idea on these bikes? 😂

@krishnachaitanyakodali7942 8 жыл бұрын

Where did you buy the gears from? I was planing on rebuilding my 1995 yzf 600r

@moardub 10 жыл бұрын

@ 29:47 what clips are you referring to that you can use that would cause the piston not to clear, the wrist pin clips? Just curious thx for such an in depth video!

@singlestallgarage 11 жыл бұрын

i got all of mine through partshark,com. however this was a year ago, and prices always go up with moto parts, they neve go down. it used to be that the typical 2nd gear rebuild was around 320$. but thats far from the case these days. other option is ebay trying to find some good used. but i think that would be the wrong way to go for this. you could swap a good used motor for not too much more than a light rebuild

@motoxx35970 11 жыл бұрын

Does the gap in the piston rings need to be set a certain way when u go to put them in the bore sleeves back in on install

@whoblowsthere002 11 жыл бұрын

Hey man, Im gonna be doing my 03 yzf600r for the same issue, shift into second and it just strips under load almost like the fork is bent preventeing it to go fully into gear and within a season its pretty much fully stripped now (gear/hub). So would I be best off pulling the motor out? Also what do you think, bent shift fork? Im a full time auto mechanic at my dads shop so any little pointers would be appreciated!

@motoxx35970 11 жыл бұрын

Need a fsms for sure lol but what all gaskets do I need and what all parts do I need to replace when I take it apart besides what's broke?

@mydan78699 12 жыл бұрын

i will be doing this one day, not paying 1500 to get it replaced at shop, would have to do it during term holiday from uni, gears are okay for now, occasionally clunking but no issues of dropping into neutral.. would it be better to buy a factory pro shift kit that some have been talking about? apparently greatly reducing the slips in the gear, also does using fully synthetic make it worse as i have heard it makes the clutch slip? cheers

@singlestallgarage 11 жыл бұрын

belive me it was a tuff call to commit the extra 100 some bucks to a new drum. but the only way to change it is with the cases split. it would suck to put it together and have a problem. this way i knew everything related to 2nd was brand new. the manual doesnt say much for drum inspection, just visuall, no numbers to go wtih it. and the drum is steel and fork is aluminum, so the drum should wear the fork, not the other way around.

@damianarden3273 7 жыл бұрын

just for the record, to any who still don't know. You do NOT have to take the top end apart to get to the transmission. the cases will split with everything attached.

@singlestallgarage 7 жыл бұрын

NO that is completely untrue. Either A: your thinking of an R6 NOT a yzf600/yzf600r/fzr600r(depending where you live), B: you are mixing up your engines C: your yzf600r engine was damaged or missing a bolt. D: are just mistaken. Definitively, from factory yzf600r, there is 1 (one) case bolt UNDER the Jugs aka cylinders. the ONLY way to get to it non destructively is to remove the cylinders. which requires the head to be removed first. That is the one and only reason you cant split the cases with the head on. it has been discussed perhaps not using that bolt in reassembly to ease future service. but I don't know of anyone who has done this. you can access the sift forks through the oil pan, but you must split cases to service the gears, and you must take the head off to get to that bolt to split the cases. hard fact, sucky, but hard fact.

@singlestallgarage 11 жыл бұрын

i dont think you will have to many issues. NO FEAR EVERYONE!!

@Massimiliano-Fauci 7 жыл бұрын

Do you also have the engine rebuild video ?

@andrewaponte8941 8 жыл бұрын

I have a question hope you read this 1997 yzf600r on 1st it ok then every other gear I have to hold the shifter with my foot in ward in order for it to stay in gear what can be the issue you think?

@whoblowsthere002 11 жыл бұрын

You made a refference to cheaper parts than I am able to find. The 5th pinion and 1st are my two bad dogs and I can't find them much less than 75.00ea. and it sounds like the drum will be well over a hundred as well. Where do you get your parts??

@kibert1 10 жыл бұрын

Amigo donde puedo buscar información de la presion de aceite que debe tener este motor..? presion y apertura de la válvula de alivio de la bomba..

@singlestallgarage 8 жыл бұрын

it is the general consensus that adding the factory pro shift kit will prevent this. also if you shift better you won't wear it. part numbers have been superseded for 2nd and 6th so maybe an improvement. I have only had 6k put on since the repair. there are others I the world with 100k on the bike with original transmission

@rwtig 8 жыл бұрын

+vashtsdaytona When you say shift better what do you mean i.e. what type of shifting would cause it to wear?

@jamesmclanders9875 7 жыл бұрын

vashtsdaytona where can one buy the factory pro shift kit?

@jdavis954 6 жыл бұрын

Hey bud do you know the torque specs for the Cam cap, head bolt, and case bolt.? The forums is down

@rukus100821 11 жыл бұрын

I was curious, did you ever think to run your "shafts" between centers? or have a machine shop check out your "casings"?. cause if you get that kind of wear that might mean something major is out of "trueness".

@plajergejmer 8 жыл бұрын

hello i have a question how the oil is suitable for yamahay yzf r6 2001 ? thanks in advance for your answer

@fernnycarvalho8463 5 жыл бұрын

Hey brother can you tell me where can I get the manual with all the torque assembly and all ?

@damianarden3273 7 жыл бұрын

yeah my bad. I knew I should've waited to post but I stupidly listened to people I thought knew what they were talking about. plus the manual didn't say anything about it. but of course it's a r6 manual. So I was wrong. I learned the hard way. but at least I got it all figured out on the parts engine at the wrecking yard and not on mine. On the bright side, I got a pristine 03 transmission for my 02 600r for $60. engines ready to drop. I just hope I can save as many gaskets as possible. Thanks for not being a dick.

@whoblowsthere002 11 жыл бұрын

As I sit here looking at exactly what you faced, ready to head to the cycle shop to place my order I can't help but leave my (like yours) minty fresh shift drum. Did you consider this; your drum is 100% O.K. and the 2,000 mile shift fork ground wrong because of a rough mating surface from the burn/scuffed/damaged gear hub it engages to? Like sticking new brake pads on a rotor that was previously ground metal to metal. I am going to see what these guys think of the "drum" idea prior to ordering.

@motoxx35970 11 жыл бұрын

Sorry about that it posted automatically but since I've had the bike it's never went into 6th gear can you help me with some troubleshooting I've never taken a bike motor apart but watching your video if I had a Haynes manual I could probably do it

@MindBlowerWTF 8 жыл бұрын

What was the code on the outer clutch basket? 4JH?

@yamrider2760 10 жыл бұрын

I have a 1996 thundercat 600 and it is stuck in second gear ? clutch is still moving plates but even when clutch is pulled in the wheel is still locked

@josephaltman1097 9 жыл бұрын

Can fix 2nd gear going through oil pan? Without taking whole motor apart?

@thatcutndude1 11 жыл бұрын

my 97 yzf600r doin the same thing right now everytime i try and shift to 2nd gear it grinds and get stuck until i kick it hard or something...i want to think its my fork is bent or something...when u get it let me kno what it was....thanks in advance

@TariroNgorosha 7 жыл бұрын

Sprag clutch 1 direction.

@singlestallgarage 11 жыл бұрын

Yes there is a pattern. I don't recall this one offhand, always buy a service manual it tells all. Join yzf600r.com forums

@bigmikeyc83 10 жыл бұрын

I was wondering if 38k on a 02 yzf 600r is too many miles on the bike . I'm thinking about buying the bike it seems to run n go good I just do want to buy it if it's gonna die soon u know .

@BruceAllentools 7 жыл бұрын

is the 01 r6 and yzf600 the same bike? my bike says r6 on the back and yzf on the front. they say the r6 you donot need to dis assemble the top end to split the case.

@vashts6176 7 жыл бұрын

Bruce Allen it is not the same. And I have also heard in r6 you can do the trans through the bottom

@BruceAllentools 7 жыл бұрын

so is mine an r6 or yzf?

@vashts6176 7 жыл бұрын

If your have 2 headlights no. yzf600r of that area has 1

@BruceAllentools 7 жыл бұрын

ive got 2 headlights. so youre saying thats the r6? if so im much happier because i know for a fact you can split the case from the bottom

@vashts6176 7 жыл бұрын

Bruce Allen yes if 2001 and two headlights that is an r6 for sure

@raleeuw Жыл бұрын

Great video,s must i remove the radiator for new sparks 1995 Fzr600 r4J greating from Holland

@vashts6176 Жыл бұрын

No you don't need to. You can either go from the top taking the tank off as there is a plastic tray under there to remove to see the plugs. Or remove the radiator mounting bolts but leave hoses. Let it sag the radiator then there is room for your hand. Blow air around plugs to remove any debris before removing plugs

@whoblowsthere002 11 жыл бұрын

I got my engine out in 2 hours. I have a PDF file for my owners manual with no transmission diagram. Do you know where I can get a blown up trans diag??? Id rather not spend 80 bucks at a cylce shop...

@MattsMadnessOfficial 10 жыл бұрын

is it possible to slit the case without taking the heads off ? I am trying to now and the case wont split in the front it has a small gap in the back of it ? I got every bolt out I think lol is there a hidden one under the jugs?

@thomashall6277 9 жыл бұрын

Matts Mower Madness Two under the jugs.

@MattsMadnessOfficial 9 жыл бұрын

yeah there was it sucked ...alot

@Joff123T 10 жыл бұрын

My clutch is slipping bad in second but not out of gear. What do I need to replace? Is it a massive job like this? If I have to do any of this I'll be watching your vid as I do it. Great stuff

@greenmarine5 9 жыл бұрын

Joff123T changing the clutch plates is fairly easy and you DO NOT need to dissemble the the engine.

@davidervin4853 9 жыл бұрын

Joff123T replace your gear box with a 2003 gear box it will sovle this problem and keep it from coming back. assuming your r6 is in bwteeen 1998 and 2002

@jamesmclanders9875 7 жыл бұрын

david ervin i have a 96 thundercat.. could i get a replacement box that solves this issue?

@motoxx35970 11 жыл бұрын

Vashdsdaytona hey man watched the vid all the way thru I'm having issues with my 98 I bought it used for 1200 dollars and it had slight issues shifting from a heavy load in to second I rode it for three days I was going down a hill down shift into first to slow down for a stop sign my back tire hopped a little I took off from the stop sign went to shift from 1st to 2nd gear it hit neutral and would not shift up now my bike is stuck in first and will only shift up two neutra and sin it had six

@ETERNALCYCLES 9 жыл бұрын

i would hate to do this chore and the shop would charge an arm for that job. I have problems shifting from 1st to second above 40kmph it either just goes to neutral or it clashes against the dogs, if i short shift its fine, just if i rev the 1st hard, getting it to 2nd becomes impossible. Is this normal in this bike or does it need a new clutch or rebuild box and would it last if i keep it easy when shifting into 2nd, it never slips out of 2nd and the clutch isnt slipping either. any opinion would be appreciated.

@randydicotti3975 8 жыл бұрын

+Universal Veritatem This problem slowly gets worse with time until finally it will start popping out of second gear one day. Mine did what yours is doing for about 3 years but yesterday it began jumping out of 2nd gear unless I was extremely light on the throttle. Ride gently and you may get another few years out of it until it needs the rebuild. Hard riding and shifting will bring it on sooner. Either way, it will eventually need it.

@2strokemadness9 18 күн бұрын

Did you do a full video of the rebuild?

@singlestallgarage 18 күн бұрын

not a full video, I only have the reassembly broken up into step by step clips. check the channel main page for them.

@damionrasberry4212 10 жыл бұрын

this guy wants me to buy his r6 it will be my first bike any takes on buying it or not because second gear slips he selling for 1800

@singlestallgarage 12 жыл бұрын

its not a very common thing to do. infact i cant recall anyone doing that switch on the forums in my 7years of being there. yzf600r.com but i have no fears using the stock tensioner. if it puts pressure on the guide it is working.

@ReV0luti0n44 10 жыл бұрын

Where can I get that tool to pull the starter clutch? Cant find 1 anywhere. Maybe I jus ain't lookin in the right place ha

@Sdavids907 10 жыл бұрын

Any generic puller will work. I'm sure a automotive harmonic balancer puller will work

@MrRednosemak 7 жыл бұрын

where's the assemble fix videos

@marknicholson2066 4 жыл бұрын

Hey there......i know this is a old video....but it was very informative.....i just picked up a 99yzf600r6 for my wife....runs great....plenty of power....but it pops in and out of 2nd under power.....so this would fix my issue correct? I called the local shop today and they want almost 4 grand to rebuild the trans......even if i pay 5 or 600 for the parts and do it myself.....im saving a shit ton of money.....sorry...maybe i sound stupid....but i mainly work on my harley and dirt bikes.....never got this far into a sport bike.....

@thefurryteddy1018 2 жыл бұрын

Yes. This is apparently a common issue because of the way yamaha cut the material. But allegedly they fixed it so when you replace the part, shouldn't happen again. Im about to do the same

@MrRednosemak 7 жыл бұрын

bro where's the assemble and mount video

@singlestallgarage 12 жыл бұрын

as long as your oil is "non energy conserving" (aka without friction modifiers) weather it be branded motorcycle oil, diesle oil, heavy duty. synthetic or dino it is fine. the friction modifiers make the clutch slip. on the container in the circle it will either say, engery conservering (you dont want that) Non energy conserving (you do want that) or nothing. nothing usually means NON energy conserving.

@motoxx35970 11 жыл бұрын

Fsms???

@singlestallgarage 11 жыл бұрын

Factory service manual

@jokaj2824 3 жыл бұрын

10:00

@Massimiliano-Fauci 7 жыл бұрын

what is the chuckle canister at 40:20 ?

@singlestallgarage 7 жыл бұрын

yup look through my channel easy to find.

@singlestallgarage 7 жыл бұрын

California model, part of emissions 07 (maybe 05+?) has them on all 50 state models.

@lplympton 7 жыл бұрын

I've got the full Cali setup on mine (Deleting it when I finish w/ this), and it's an '04

@randydicotti3975 8 жыл бұрын

The problem with doing this is that AFAIK, it will come back in 15 - 20K miles again. Unless the parts have been improved? I don't know.

@karterclayton6175 2 жыл бұрын

I dont mean to be so off topic but does someone know of a way to log back into an Instagram account? I stupidly lost my login password. I appreciate any tips you can offer me

@beaureed564 2 жыл бұрын

@Karter Clayton Instablaster ;)

@karterclayton6175 2 жыл бұрын

@Beau Reed thanks so much for your reply. I got to the site thru google and Im trying it out atm. Takes quite some time so I will reply here later with my results.

@karterclayton6175 2 жыл бұрын

@Beau Reed it worked and I now got access to my account again. I am so happy:D Thanks so much, you really help me out!

@beaureed564 2 жыл бұрын

@Karter Clayton you are welcome =)