Fazer Owners Club - Unofficial

Bikes, Hints'n'Tips => FZS600 Fazer => Topic started by: Dcock on 13 May 2014, 08:14:42 pm

Title: Replacing selector forks and drum
Post by: Dcock on 13 May 2014, 08:14:42 pm
Hi, i have a 1998 fzs600 and since i have had the bike it has been very clunky/sometimes grinds/crunches when going from 1st to second and from second to third. Also there is significant whining noise while in second gear. Does this sound likely to be a bent selector fork or worn drum? If so i heard that these can be replaced with the engine still in the frame with the sump removed and clutch out. I replaced the cam chain on this bike and fork oil/seals etc so feel confident i could do this job. Any ideas on what it could be or info about replacing the selector forks would be appreciated.


Cheers, Dan
Title: Re: Replacing selector forks and drum
Post by: Deefer666 on 14 May 2014, 07:32:34 am
Normally the bike will start jumping out of 2nd and quickly end up with no 2nd gear at all. Here is my method that I use to change the selector mechanisms on FZS600s....

ok if you have a Haynes manual/book of lies ignore it completely from here on in:

Drain oil.
remove down pipes
remove sump
remove clutch casing
remove entire clutch basket (withdraw push rod and don't lose the ball bearing that sits in the basket end)
remove oil pump
remove the gear lever
remove gear selector shaft
remove the sprung wheel that the selector drum runs on (making sure that its in neutral and taking note of how the mechanism goes back in)
remove the bolts that hold the fork shafts in place
 
Now the next section is easier if you have a bike bench otherwise you have to do it laying on your back

slowly withdraw the rear rod that the left and right forks run on (the forks should not come out but just make sure you steady them as the rod comes out so the don't wedge against the gears)
repeat with the front rod that holds the centre fork
now carefully remove the drum and remove the forks as the drum comes out.
make note of how the forks go in (they are marked left, right, and centre)

now clean and examine the drum and forks. normally the drum is fine but the forks especially the centre will have been worn and it will be obvious which is causing the problem, REPLACE ALL THREE, the drum can normally be reused.

Now replace the drum but don't secure it in place just yet but make sure neutral is pointing down to the six o'clock position
locate the two new rear forks then slide the rod into place guiding the forks into the correct position as you go
do the same to the front/centre fork.
refit everything inside the engine making sure that the oil pump shaft mates securely with the water pump shaft when refitted
cycle through the gears by hand before refitting the clutch casing just to make sure

refit clutch casing, sump, and pipes, fill with oil
strut around the garage in a manly way and sup tea whilst bragging to your mates/wife/kids that you are a truly great spanner monkey!

Job done!

**NOTE** This is not a novice job and I may have omitted and item or two as I am typing it from memory but that will become obvious if you attempt the task. My local Yamaha dealer still insist its an engine out and split job but I have done this for several of my customers without issue, but saying that unless I am actually doing the job I do not take responsibility for anyone using this post to fix their own bike, so if you arse it up don't blame me.....  Thank you.

Title: Re: Replacing selector forks and drum
Post by: Dcock on 14 May 2014, 01:51:08 pm
Thats an amazing reply. Thanks a lot for that Deefer. Would you suggest not doing this until it starts jumping out of second gear? Or are you thinking this problem may not be related to the selector forks?
Title: Re: Replacing selector forks and drum
Post by: His Dudeness on 14 May 2014, 02:16:07 pm
Good write up but I hope I never have to use it!
Title: Re: Replacing selector forks and drum
Post by: Deefer666 on 14 May 2014, 02:40:43 pm
Have you cleaned out & regreased the clutch push mechanism in the sprocket cover, and then reset the tension on the push rod? That's where I would be heading first before delving into the gearbox.
Title: Re: Replacing selector forks and drum
Post by: Dcock on 15 May 2014, 05:15:06 pm
I remember adjust the pushrod system a while ago when I first noticed the gear change trouble. Just to clarify is it the mechanism behind the rubber plug on/by the front sprocket cover? Although I dot remember regreasing it.
Title: Re: Replacing selector forks and drum
Post by: darrsi on 15 May 2014, 06:18:43 pm
I remember adjust the pushrod system a while ago when I first noticed the gear change trouble. Just to clarify is it the mechanism behind the rubber plug on/by the front sprocket cover? Although I dot remember regreasing it.



Have a read of this thread about sprocket cover.


http://foc-u.co.uk/index.php/topic,10124.0.html (http://foc-u.co.uk/index.php/topic,10124.0.html)
Title: Re: Replacing selector forks and drum
Post by: Hawko on 24 May 2016, 09:42:45 am
Normally the bike will start jumping out of 2nd and quickly end up with no 2nd gear at all. Here is my method that I use to change the selector mechanisms on FZS600s....

ok if you have a Haynes manual/book of lies ignore it completely from here on in:

Drain oil.
remove down pipes
remove sump
remove clutch casing
remove entire clutch basket (withdraw push rod and don't lose the ball bearing that sits in the basket end)
remove oil pump
remove the gear lever
remove gear selector shaft
remove the sprung wheel that the selector drum runs on (making sure that its in neutral and taking note of how the mechanism goes back in)
remove the bolts that hold the fork shafts in place
 
Now the next section is easier if you have a bike bench otherwise you have to do it laying on your back

slowly withdraw the rear rod that the left and right forks run on (the forks should not come out but just make sure you steady them as the rod comes out so the don't wedge against the gears)
repeat with the front rod that holds the centre fork
now carefully remove the drum and remove the forks as the drum comes out.
make note of how the forks go in (they are marked left, right, and centre)

now clean and examine the drum and forks. normally the drum is fine but the forks especially the centre will have been worn and it will be obvious which is causing the problem, REPLACE ALL THREE, the drum can normally be reused.

Now replace the drum but don't secure it in place just yet but make sure neutral is pointing down to the six o'clock position
locate the two new rear forks then slide the rod into place guiding the forks into the correct position as you go
do the same to the front/centre fork.
refit everything inside the engine making sure that the oil pump shaft mates securely with the water pump shaft when refitted
cycle through the gears by hand before refitting the clutch casing just to make sure

refit clutch casing, sump, and pipes, fill with oil
strut around the garage in a manly way and sup tea whilst bragging to your mates/wife/kids that you are a truly great spanner monkey!

Job done!

**NOTE** This is not a novice job and I may have omitted and item or two as I am typing it from memory but that will become obvious if you attempt the task. My local Yamaha dealer still insist its an engine out and split job but I have done this for several of my customers without issue, but saying that unless I am actually doing the job I do not take responsibility for anyone using this post to fix their own bike, so if you arse it up don't blame me.....  Thank you.

Hey Deefer, do you atill work on other bikes at all? As i have a stuck gear lever and nbot competent enought to do the above fixes?

Cheers
Hawko (Bedford)
Title: Re: Replacing selector forks and drum
Post by: Fazerider on 24 May 2016, 10:31:57 am
... Would you suggest not doing this until it starts jumping out of second gear?

It's best to sort it before it gets bad. Every time you get that grinding noise it damages the dogs on the gears, if they get too badly rounded off the bike will jump out of gear and the solution then is to replace them... that cannot be done without taking the engine out and splitting the cases.
I had a problem engaging 1st and 2nd and thought replacing the forks and drum might be the solution.
My experience of doing the job is here:
http://foc-u.co.uk/index.php?topic=13507 (http://foc-u.co.uk/index.php?topic=13507)
Title: Re: Replacing selector forks and drum
Post by: darrsi on 24 May 2016, 04:23:20 pm
... Would you suggest not doing this until it starts jumping out of second gear?

It's best to sort it before it gets bad. Every time you get that grinding noise it damages the dogs on the gears, if they get too badly rounded off the bike will jump out of gear and the solution then is to replace them... that cannot be done without taking the engine out and splitting the cases.
I had a problem engaging 1st and 2nd and thought replacing the forks and drum might be the solution.
My experience of doing the job is here:
[url]http://foc-u.co.uk/index.php?topic=13507[/url] ([url]http://foc-u.co.uk/index.php?topic=13507[/url])


2 year old post Fazerider.  ;)
Title: Re: Replacing selector forks and drum
Post by: Fazerider on 25 May 2016, 10:11:33 am
... Would you suggest not doing this until it starts jumping out of second gear?

It's best to sort it before it gets bad. Every time you get that grinding noise it damages the dogs on the gears, if they get too badly rounded off the bike will jump out of gear and the solution then is to replace them... that cannot be done without taking the engine out and splitting the cases.
I had a problem engaging 1st and 2nd and thought replacing the forks and drum might be the solution.
My experience of doing the job is here:
[url]http://foc-u.co.uk/index.php?topic=13507[/url] ([url]http://foc-u.co.uk/index.php?topic=13507[/url])


2 year old post Fazerider.  ;)

Doh! Missed that. :lol


Though the link may be of use to Hawko since his sounds pretty much like the problem I had.