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Yamaha Yzf600r Thundercat gearbox fix thread
I have started the mammoth task of getting my bike in pieces so I can first take a look at the gearbox then secondly, hopefully, fix it.
Few start off pictures shall we?
http://s15.postimage.org/k8oxuk58n/image.jpg
http://s15.postimage.org/ygj7wy7bb/image.jpg
So got all fairings off that I need to. Ive got the sprocket cover off. Disconnected the battery and drained the oil.
Next session will be drain coolant, remove radiator, water pump, piping etc. Then remove the exhaust. Remove petrol tank and start to strip the Carbs down on the engine.
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Re: Yamaha Yzf600r Thundercat gearbox fix thread
safer/easier to take tank off now before you start messing with the rest?
good luck with it tho
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Re: Yamaha Yzf600r Thundercat gearbox fix thread
DON'T remove the water pump before dropping the engine out! That'll leave a big hole into your gearbox that any crap can get into, even if you're splitting the engine you still don't want anything untoward inside it.
Someone may have mentioned already somewhere, give your exhaust header clamp nuts a good spray with WD40 or similar and let them soak for a while, they may not have been disturbed since the bike was new and a snapped exhaust stud is a pain in the arse >:(
If there's a garage close by it might be worth asking if you could push it round there for them to use a rattle gun to loosen the clutch centre nut and your front sprocket nut too, you could struggle with them otherwise (ask first and if they will, take off the clutch cover and remove the pressure plate and all the friction plates, then refit the cover to push it round. Either that or borrow a compressor and rattle gun from someone)
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Re: Yamaha Yzf600r Thundercat gearbox fix thread
Will brute force work too? I am nowhere near pushing distance of a bike garage or any mechanics garage. I'll keep mister water pump on then but take his arms(pipes) off.
Anyone any idea how much the engine will weight roughly in KG? Bikes whole weight is 187kg.
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Re: Yamaha Yzf600r Thundercat gearbox fix thread
If you can get sufficient leverage then pure torque will do it, but you may need a breaker bar a metre long and maybe a lump hammer to assist by giving the back of the socket a tap when it's loaded up. Use a length of wood through the rear wheel to lock it against the swingarm.
The engine will probably be getting on for half the mass of the bike. Unless you're unfeasibly strong and dexterous it's a 2-person job to remove, refitting is easier with three.
RTFM will really help, do that first....
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Re: Yamaha Yzf600r Thundercat gearbox fix thread
You have a garage...yes? You're not doing this outside your house shirley?
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Re: Yamaha Yzf600r Thundercat gearbox fix thread
Get the exhaust off. Soak it in WD40 for days, then tackle. Is going to be the worst bit.
Agreed with Scotty, wedge the read wheel and with a breaker bar and hammer, shock the sprocket nut off. If you can VERY carefully apply heat to the nut, it will break any thread lock in there.
As to the engine, I imagine that it is going to be the better part of 100kg. You'll need two or three people to get it out the bike safely.
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Re: Yamaha Yzf600r Thundercat gearbox fix thread
Quote:
Originally Posted by Scotty
RTFM will really help, do that first....
Excuse the interruption guys but whats RTFM? Only ask cause might have to have mine in bits
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Re: Yamaha Yzf600r Thundercat gearbox fix thread
Really Tight Flux Manipulator.
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Re: Yamaha Yzf600r Thundercat gearbox fix thread
Aint that stupid Mitch.....an it aint a deloren either ;)
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Re: Yamaha Yzf600r Thundercat gearbox fix thread
Quote:
Originally Posted by porkies
[quote author=Scotty link=1332878940/4#4 date=1332912106]
RTFM will really help, do that first....
Excuse the interruption guys but whats RTFM? Only ask cause might have to have mine in bits
[/quote]
Read The Fxxxing Manual
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Re: Yamaha Yzf600r Thundercat gearbox fix thread
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Re: Yamaha Yzf600r Thundercat gearbox fix thread
Considering this section is called Technical help etc etc RTFM is ummmm not a very subtle way of saying 'purchase the manual and have a read through'
Also, youtube is an excellent way of finding stuff out......but there are lots of people on here who like hearing about the challenges others face when trying to fix their bikes and turn to those of you who really do have some expert knowledge on different problems faced.
I know I turn to one or two of the clever bikey types who know loads in the hope of gaining a little insight into the problems a manual doesnt tell you about. :P :P :P
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Re: Yamaha Yzf600r Thundercat gearbox fix thread
Quote:
Originally Posted by Tina
Considering this section is called Technical help etc etc RTFM is ummmm not a very subtle way of saying 'purchase the manual and have a read through'
Also, youtube is an excellent way of finding stuff out......but there are lots of people on here who like hearing about the challenges others face when trying to fix their bikes and turn to those of you who really do have some expert knowledge on different problems faced.
I know I turn to one or two of the clever bikey types who know loads in the hope of gaining a little insight into the problems a manual doesnt tell you about. :P :P :P
WELL SAID.
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Re: Yamaha Yzf600r Thundercat gearbox fix thread
Today ive been out and bought lots of wood. Made myself a new work bench. Will post pics up. Decided I needed somthing to put the engine on when working on it!!
Im not exactly worlds strongest man but could lift it up onto a bench without major struggle at around 100kg.
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Re: Yamaha Yzf600r Thundercat gearbox fix thread
i lifted my engine into my van on my own ohhh eat weetabix ;D
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Re: Yamaha Yzf600r Thundercat gearbox fix thread
If your stuck I do have large breaker bars,a toque wrench or two and compressor and knocking gun, not short of tools :-)
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Re: Yamaha Yzf600r Thundercat gearbox fix thread
The clutch centre nut is torqued to 70nm (about 56ftIb) but there is a lock tab washer on it aswell.
i took my TDM clutch off few months ago no problem got a clutch holding tool to do the job.
Where are you i got a Haynes manual you can have for the Thundercat,plus i think the clutches are the same if im correct
It will be easier to undo the torqued nut ie clutch with engine in the frame
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Re: Yamaha Yzf600r Thundercat gearbox fix thread
Have a read of this mate
http://www.offwidth.co.uk/bike/cat/engine.html
It's what I followed the first time I took my Thundercat engine out.
I've lost your number by the way because I'm a tool so drop me a text and we'll sort something out if you want some help, it's not the weight of the engine it's the shape that's the killer, I got mine in and out of the boot of a Yaris on my own but to drop it out and put it back in the frame I'd say you want two or three people. You really want someone on the jack, someone taking the weight of the engine and another watching so they can spot if you've forgotten to undo anything and to tell the Jack person to stop.
Oh, I have a rattle gun too that will probably come in handy
; ) Especially on the nut holding the rotor on
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Re: Yamaha Yzf600r Thundercat gearbox fix thread
Hows it coming on ash, no update this week?.
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Re: Yamaha Yzf600r Thundercat gearbox fix thread
Ended up buying a new car so the bike took a step back, Will be getting back onto it this weekend and hopefully getting the engine out fully!
Bench picture http://a6.sphotos.ak.fbcdn.net/hphot...11849342_n.jpg
Sturdy as a rock!
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Re: Yamaha Yzf600r Thundercat gearbox fix thread
few issues with taking the carbs off. Cant get my fat hands or fat head to see where the allen holding the clasp on numbers 3+4. (far right and right center)
tempted to just lift the engine out with them still attached and then take it off if required after ive got the engine out??
Any issues with doing this, ie damaging the carbs or anything else if any spilled (presuming there will be fuel still in the carbs.)
Thanks.
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Re: Yamaha Yzf600r Thundercat gearbox fix thread
There will be fuel in the float chambers at the bottom of the carbs. The main issue would be clearance / access to lifting points when removing the engine - I would say if you are happy they are not in the way or will get damaged when hoisting the engine out they could stay in place. Make sure all the lines and cables going to them are detached before seprtating of course.
The fuel in them will gum up over time. Going over into other angles while engine out may let some of the fuel run into the top end and thin out the engine oil. Given what you have coming up that'll be changed anyway. There should be drains on the bottom of each float bowl if you want to drain the fuel out of them first.
Once you have them off the engine of left on with the airbox off get some plastic bags, or paper towel to fill the openings (venturi?)'s so any dirt or dropped nut, washer etc doesn't go find a new home near your inlet valves or top of piston.
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Re: Yamaha Yzf600r Thundercat gearbox fix thread
Alright Ash, how's it going?
Don't forget I have stuff I could bring around to help you out, like a rattle gun ; )
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Re: Yamaha Yzf600r Thundercat gearbox fix thread
Engine out :
http://i46.tinypic.com/14joxnp.jpg
Carbs off:
http://i49.tinypic.com/1zoayvr.jpg
Bottom sump casing off for a sneak peak:
http://i48.tinypic.com/2ps2grc.jpg
F*ck. Gears completely nackered and snapped to pieces, no idea what has caused it!!
Pieces of the cog that I managed to scrape out the bottom of the sump.
http://i50.tinypic.com/2evxocn.jpg
Anyone know if this is worth repairing, should that be the only part thats damaged?
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Re: Yamaha Yzf600r Thundercat gearbox fix thread
ouch :o would it not be easier/cost effective to source a new engine? and just drop that in
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Re: Yamaha Yzf600r Thundercat gearbox fix thread
Ooooeeerrrrr...... that looks nasty.
You'll have to take the sump off to fully assess that. If the damage is only there and the gears are easy to source then I'd repair. If not a new engine gearbox is your best option. Just check that this isn't a known weakness with these as you could buy another engine and find it's lunched!
Bet your learning loads from this though!!! :)
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Re: Yamaha Yzf600r Thundercat gearbox fix thread
Started last night to strip top of the engine down. I will take to pieces before thinking of buying any other parts. Got a manual to help take apart and few kind offers should I get stuck!
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Re: Yamaha Yzf600r Thundercat gearbox fix thread
Down to splitting the very last cases. I can't get it apart. I may have missed a bolt but can't find number 19 from the lower casing.
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Re: Yamaha Yzf600r Thundercat gearbox fix thread
Finally got the bugger apart.
Pictures of internals:
http://www.picoolio.com/show/57101/5ayc5
Not sure if this link is working?
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Re: Yamaha Yzf600r Thundercat gearbox fix thread
if not, this is the main culprit with the opposite gear's teeth sheared off too. Just working out how much each gear costs, mixed with £120 gasket set, 4litres oil, 3litres coolant...
http://imageshack.us/photo/my-images...243916493.jpg/
I am VERY worried about putting it all back together.. around the side parts. Proper FML as I got anoyed and didnt label or bag the last sets of screws.
I also have a small ballbearing which literally appeared from nowhere. Any ideas anyone? Its about 6mm in diameter silver ball
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Re: Yamaha Yzf600r Thundercat gearbox fix thread
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Re: Yamaha Yzf600r Thundercat gearbox fix thread
No. Yours is an FZR engine, that is a R6. I think you need to find an old Genisis.
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Re: Yamaha Yzf600r Thundercat gearbox fix thread
Cheers chaps, will go with the gaskets then.
GEAR, 3RD PINION (22T) £146 ..
GEAR, 4TH WHEEL (28T) £90
Starter crankcase gasket £7.60
Clutch crankcase gasket £12.20
Cyclinder Gasket £14.10
Headcover gasket is still looking good.
Cylinder head gasket £37.30
Water pump gasket £0.60
Sump Gasket £11.50
Total £320.81 posted
Oil filter £6
Spark plugs £22.50
Oil 4litres 10/40 £25
Coolant 3litres £21
Total £74.50
Cant find the gasket for the main crankcase, if there is one?
http://www.yamahamotorcyclespares.co...ageID=14&m...
£395.31
buying parts from Ajsutton site, Cant really find anywhere else thats got any parts available!
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Re: Yamaha Yzf600r Thundercat gearbox fix thread
There isn't a main crankcase gasket - there isn't a complete gasket face around the entire cases and the surfaces have to mate directly to maintain the correct clearance on all the main bearings in addition to the gearbox bearings. Usually a sealant is used, in this case Yamabond, in moderate quantities - Read the manual!
As said previously, use the regular gaskets elsewhere.
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Re: Yamaha Yzf600r Thundercat gearbox fix thread
Have a butchers here
http://www.wemoto.com/bikes/yamaha/y..._athena_italy/
Don't forget, look at both 2nd gear and 3rd gear cogs at the dogs and don't forget the 6th gear cogs that they connect with, you want to chack to see if the recesses that the dogs go into are worn on the edges.
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Re: Yamaha Yzf600r Thundercat gearbox fix thread
http://www.ebay.co.uk/itm/Yamaha-FZ6...893eefb38#shId
from a fazer, maybe not quite the same as its an 05 fazer from US? Would this fit?!
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Re: Yamaha Yzf600r Thundercat gearbox fix thread
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Re: Yamaha Yzf600r Thundercat gearbox fix thread
Quote:
Originally Posted by supermancss
Cheers chaps, will go with the gaskets then.
GEAR, 3RD PINION (22T) £146 ..
GEAR, 4TH WHEEL (28T) £90
Starter crankcase gasket £7.60
Clutch crankcase gasket £12.20
Cyclinder Gasket £14.10
Headcover gasket is still looking good.
Cylinder head gasket £37.30
Water pump gasket £0.60
Sump Gasket £11.50
Total £320.81 posted
Oil filter £6
Spark plugs £22.50
Oil 4litres 10/40 £25
Coolant 3litres £21
Total £74.50
Cant find the gasket for the main crankcase, if there is one?
http://www.yamahamotorcyclespares.co...ageID=14&m...
£395.31
buying parts from Ajsutton site, Cant really find anywhere else thats got any parts available!
Have you tried Fowlers of Bristol they have next day delivery,
I use to be a member of the MSN Thundercat group but here is a link to the new site will have lot of info on there http://www.yamaha-thundercats.org/f39-the-workshop.
Might be worth joining
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Re: Yamaha Yzf600r Thundercat gearbox fix thread
Quote:
Originally Posted by supermancss
www.ebay.co.uk/itm/Yamaha-FZ6-FZ-6-600-FZ600-Fazer-05-Engine-Transmission-Set-Tranny-06-07-F-2005-/380439034680?pt=Motorcycles_Parts_Accessories& hash=item5893eefb38#shId
from a fazer, maybe not quite the same as its an 05 fazer from US? Would this fit?!
You need parts from a 1996 - 2002 fazer 600 they are the same engine only detuned with slight differences to carbs and camshafts.When they updated the Fazer 600 they then used the R6 engine