FZS600 02 engine and gear box issues

[tex1507]

Hi All,

My 02 fazer has just gone past the 60000 mark and has developed a couple of issues:-
First off I am getting an annoying knock which sounds like it is coming from the top end, couple of local bike shops have told me not to worry as these are just 'wear noises due to the mileage' which I am a little dubious about.
Second :- changing gear has become difficult, all the gears can be selected and don't jump out however when changing up the gearbox feels very stiff with the gear level remaining in the up position for several seconds before returning to the normal position.
this only happens changing up the gears, changing down the gears everything feels normal.
Any ideas what could be causing these and are the they an easy fix?

Cheers

Stu

[Jules-C]

Take the sprocket cover off to check the gear lever shaft isn't sticking in the outer casing due to dirt or corrosion.  Or drown it in your maintenance/lubricant spray of choice to see if it frees it a bit before taking sprocket cover off.

[darrsi]

If you can hear the knocking noise on tickover record the sound or post a video so we can hear it.

When was the last time you properly adjusted your clutch cable, bottom end as well as top?
I'd adjust that first and see if it helps.
Is the cable okay as well, or is it possibly on its way out?
Always worth trying the easiest/cheap options first.

[tex1507]

I adjusted the cable at last service and checked it over, when I get a chance I will record the sound and see if I can post it here.

[Deefer666]

Have you removed you front sprocket cover and cleaned the accumulated shite out from around the clutch push mechanism? You will need to regrease it afterwards and then readjust the clutch at the bottom end.

[Gnasher]

Have you removed you front sprocket cover and cleaned the accumulated shite out from around the clutch push mechanism? You will need to regrease it afterwards and then readjust the clutch at the bottom end.

:agree

With the bike approaching 60k has the clutch been ever been looked at or checked?  They dont last forever and it's possible this one has reached the end of it's servicable life and needs new springs, plates cable etc. 

[tex1507]

Right quick update,
Sprocket cover removed and all shite cleaned out as a precaution have also replaced the clutch cable end result
gear box has never been smoother.
however I have a coupe of sound recordings of the engine how do I upload them to the site?

[Deefer666]

Right quick update,
Sprocket cover removed and all shite cleaned out as a precaution have also replaced the clutch cable end result
gear box has never been smoother.
however I have a coupe of sound recordings of the engine how do I upload them to the site?

:thumbup  Normally the gears are something simple like the push mechanism being gunked up.

[Deefer666]

[quote author=tex1507 link=topic=15829.msg183205#msg183205 date=1423728803]
Right quick update,
Sprocket cover removed and all shite cleaned out as a precaution have also replaced the clutch cable end result
gear box has never been smoother.
however I have a coupe of sound recordings of the engine how do I upload them to the site?

:thumbup  Normally the gears are something simple like the push mechanism being gunked up. where abouts in the country are you, if you are anywhere near me Ill take a listen.
[/quote]

[Fazafou]

Do you run a k&n air filter by any chance?

[tex1507]

Hi Deefer

I have commuted from brum to a customer in Luton today, but normally in and around Jct2 of the M42 if that helps.
Fazerfou nope just a Std Hiflo filter.

[darrsi]

Hi Deefer

I have commuted from brum to a customer in Luton today, but normally in and around Jct2 of the M42 if that helps.
Fazerfou nope just a Std Hiflo filter.

It was a cheap Hi/Flo filter that made me quickly buy a K&N, I had it in for about a week then realised the bike was underperforming, as if it couldn't breathe.
I binned it straight after I changed it.

When I mentioned it on here someone else said they had exactly the same issue as well with a Hi/Flo filter.

[Deefer666]

I have never had a problem with the Hi Flo filters when I used them, although that was a while ago and I have switched to Yamaha own. I am struggling to see how a filter would cause a knock on the top end.


My workshop is just off the A14 near thrapston if you are over this way

[darrsi]

I have never had a problem with the Hi Flo filters when I used them, although that was a while ago and I have switched to Yamaha own. I am struggling to see how a filter would cause a knock on the top end.


My workshop is just off the A14 near thrapston if you are over this way

For me it was just a passing comment as I remember the Hi-Flo filter suffocating my bike.
Other than that, I doubt there is any real relevance.  :lol