Lost All Drive To The Rear Wheel

[groundhogdaze]

Hope someone can help me. I have a 2002 FZS 600. Had it for about a year and it has had occasional clutch slip on it when revved hard. Today I was out driving on a motorway travelling at 70mph when the clutch seemed to slip and all drive to the back wheel has failed. Got the bike recovered to get home. The engine runs and I can put the bike into gear and go through the box up and down but no drive. There is a noise coming from the casing where the clutch cable goes into the gearbox/clutch housing and this goes away if I pull the clutch lever in.


A friend has suggested that the output shaft has broken  - any ideas?

[flakey]

you could check to see if the front sprocket is still in place with the big nut in front of it, a common fault on early fazers was the nut coming undone-worth checking

[Jules-C]

Or sprocket got all the teeth worn off it!

But sprocket cover off first to see what's going on

[Bretty]

The left side casing is dead easy to remove and take a look. Only need to remove the gear lever linkage with a 10mm spanner, then 4 x 5mm caphead screws.

Broken output shaft sounds a bit odd, could it be the sprocket nut has failed? with the left casing removed you'll be able to see/touch it.
Or possibly something has happened to the clutch basket on the right side?

If either gearbox shaft is damaged it's an engine out and split job. If it's a clutch issue that's a lot easier to sort.

[groundhogdaze]

Thank you guys - that is the problem, the nut came loose and has disappeared - must have worn down. Anybody know what size the nut is and what the thread pitch is so I can get a new o tomorrow and threadlock it.

[unfazed]

Are the threads damaged? if so check this out http://foc-u.co.uk/index.php?action=downloads;sa=view;down=43

The Nut and Tab Washer you need is part number 90891-10124 (Includes both) it is about £3. in Fowlers or Wemoto

[groundhogdaze]

Thanks, I should hopefully get away with some threadlock as the threads don't seem too bad.

[unfazed]

Buy and fit the sprocket cover plate and damper which was fitted to the 98-99 models and it will stop the nut falling off completely which prevents the sprocket coming off.

Happen to mine years ago and damaged the threads enough that thread lock did not help, which was why I fitted the plate.
You will have to thread the holes in the plate to fit it