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Gen 1 gearbox issue - Printable Version

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Gen 1 gearbox issue - Rodster - 30-09-25

Hi,

I had my first hard ride out on the bike at the weekend, when I’m on full throttle in first or second and the front end is …. Well going up, when I bring the front down the bike pops into neutral off throttle , it also does it going over a hump back bridge and letting off the throttle. Never had a bike do this, I know the answer is stop being an idiot but..anyway.

the bike has been babied by the old owner for 8 years and he got it with 7k on the clock, and now it has 11200 miles 

Bike has had plenty of services and I have just done another with Motul oil etc.

The shift linkages are free and working
It does have a R6 shift arm (same as Richard Marks) 
Clutch has free play and doesn’t slip
I can’t replicate it on demand only in certain situations.

Has anyone had this or can you offer any advice aside stop being stupid ?

Regards
Rodster


RE: Gen 1 gearbox issue - RMT1983 - 30-09-25

Welcome to the group mate! Hopefully one of the older mpre experienced gents can help ?


RE: Gen 1 gearbox issue - Rodster - 30-09-25

(30-09-25, 10:42 PM)RMT1983 Wrote: Welcome to the group mate! Hopefully one of the older mpre experienced gents can help ?

Thankyou mate, now I have two places to bug people aside the Facebook group ?
hoping it’s something simple, the box doesn’t look fun at all to remove.


RE: Gen 1 gearbox issue - Gnasher - 01-10-25

Check the clutch and shift lever are correctly adjusted, operate smoothly and don't have excessive wear in their Mechanisms.

Potentially you are looking at either selector drum/fork and or driving dog/gear damage or wear.


RE: Gen 1 gearbox issue - Rodster - 01-10-25

(01-10-25, 07:31 AM)Gnasher Wrote: Check the clutch and shift lever are correctly adjusted, operate smoothly and don't have excessive wear in their Mechanisms.

Potentially you are looking at either selector drum/fork and or driving dog/gear damage or wear.

Thankyou for the reply, I was thinking it could be something in the selector drum, I know on some of my old bikes, companies like factory pro offer a upgraded version of the shift detent kit  to assist with shifts etc but looks like Yamaha got it right as I can’t seem to find one, I would prefer changing that than stripping the engine ?

I will recheck the clutch at the weekend


RE: Gen 1 gearbox issue - Gaz66 - 01-10-25

(30-09-25, 10:23 PM)Rodster Wrote: Hi,

I had my first hard ride out on the bike at the weekend, when I’m on full throttle in first or second and the front end is …. Well going up, when I bring the front down the bike pops into neutral off throttle , it also does it going over a hump back bridge and letting off the throttle. Never had a bike do this, I know the answer is stop being an idiot but..anyway.

the bike has been babied by the old owner for 8 years and he got it with 7k on the clock, and now it has 11200 miles 

Bike has had plenty of services and I have just done another with Motul oil etc.

The shift linkages are free and working
It does have a R6 shift arm (same as Richard Marks) 
Clutch has free play and doesn’t slip
I can’t replicate it on demand only in certain situations.

Has anyone had this or can you offer any advice aside stop being stupid ?

Regards
Rodster

Hi Rod.

Welcome to the forum.

Gearbox may well have been abused by previous owners, mileage means nothing.
Bikes got a ton of grunt, achieves nowt nailing it thru lower gears, these old Yamaha motors have what I'd describe as an agricultural gearbox.
Many of us have an early R1 shift arm fitted, shorter throw, needs a tad more lever effort imho, R6 may use exact same arm?


A few quick things to check:
1) Any stiffness in the rose joints on shift lever & shift arm?
2) Gear lever free & pivot greased?
3) Shift rod dragging on inside of frame tunnel? (common issue with shorter throw shift arms as offset is different causing shift rod to frame contact, R1 shift arm requires a mod to shift rod, bend a slight kink to clear any frame contact) 
4) Upper shift arm correctly orientated 90 degrees to shift rod? (pics will be useful)

First place I'd be looking before dropping the motor & stripping the box is inside the upper selector shaft casing, shift shaft runs thru a needle bearing & oil seal, bearing could be worn, shaft could be mullered / bent & dragging in the bearing, return spring may be weak/bent/cracked, order a new spring & gasket from Yamaha in advance, most of us use "Fowlers" for obvious reasons.

This is where you'd be accessing the selector drum to fit the "Factory Pro shift star kit" they'll probly be available to fit this motor, but listed as 1998/1999 R1 fitment, basically same motor.
Shift star kits are spensive, defo won't solve a jumping out of gear issue,  it'll make things worse, wear of damage is the most likely cause of jumping outta gear.

Let us know how you get on?


RE: Gen 1 gearbox issue - Rodster - 02-10-25

(01-10-25, 11:33 PM)Gaz66 Wrote:
(30-09-25, 10:23 PM)Rodster Wrote: Hi,

I had my first hard ride out on the bike at the weekend, when I’m on full throttle in first or second and the front end is …. Well going up, when I bring the front down the bike pops into neutral off throttle , it also does it going over a hump back bridge and letting off the throttle. Never had a bike do this, I know the answer is stop being an idiot but..anyway.

the bike has been babied by the old owner for 8 years and he got it with 7k on the clock, and now it has 11200 miles 

Bike has had plenty of services and I have just done another with Motul oil etc.

The shift linkages are free and working
It does have a R6 shift arm (same as Richard Marks) 
Clutch has free play and doesn’t slip
I can’t replicate it on demand only in certain situations.

Has anyone had this or can you offer any advice aside stop being stupid ?

Regards
Rodster

Hi Rod.

Welcome to the forum.

Gearbox may well have been abused by previous owners, mileage means nothing.
Bikes got a ton of grunt, achieves nowt nailing it thru lower gears, these old Yamaha motors have what I'd describe as an agricultural gearbox.
Many of us have an early R1 shift arm fitted, shorter throw, needs a tad more lever effort imho, R6 may use exact same arm?


A few quick things to check:
1) Any stiffness in the rose joints on shift lever & shift arm?
2) Gear lever free & pivot greased?
3) Shift rod dragging on inside of frame tunnel? (common issue with shorter throw shift arms as offset is different causing shift rod to frame contact, R1 shift arm requires a mod to shift rod, bend a slight kink to clear any frame contact) 
4) Upper shift arm correctly orientated 90 degrees to shift rod? (pics will be useful)

First place I'd be looking before dropping the motor & stripping the box is inside the upper selector shaft casing, shift shaft runs thru a needle bearing & oil seal, bearing could be worn, shaft could be mullered / bent & dragging in the bearing, return spring may be weak/bent/cracked, order a new spring & gasket from Yamaha in advance, most of us use "Fowlers" for obvious reasons.

This is where you'd be accessing the selector drum to fit the "Factory Pro shift star kit" they'll probly be available to fit this motor, but listed as 1998/1999 R1 fitment, basically same motor.
Shift star kits are spensive, defo won't solve a jumping out of gear issue,  it'll make things worse, wear of damage is the most likely cause of jumping outta gear.

Let us know how you get on?

Thankyou for your reply, tonight I did the following -
Checked the rose joints, they move freely
Checked, cleaned and greased the gear pivot, it was free but thought it was worth doing. 
Checked it wasn’t hitting the tunnel, it has good clearance 
The shift feels solid (good) and returns to the center. I think the springs etc are good, but I may remove and replace them this winter just as a precaution 
Added more free play to the clutch 
Checked the chain tension, in spec 

Other than that maybe I just didn’t select the gear right but I have a feeling I’m being hopeful. 

Oh and get this ! I took my lightly resorted GPZ 500 out for its first ride tonight, and low and behold that actually has a proper gearbox issue, they are renowned for the gen 1 having bad boxes that pop out of gear so that’s getting a Gen 2 transmission over winter. 

Maybe it’s me ?