FZRSupport: the FZROnline Archive

Hey everyone,

So Im at the point where I want to get my 87 1000 on a track. The only issue I have is my shift from 1 to 2 sometimes misses under hard acceleration. Ive found through this forum that its cause is the shift fork being bent, and it will only get worse with time. Obviously this is an issue on a track as I'll be accelerating hard and then shifting.

I have the Haynes FZR600/750/1000 87-96 manual. So I have a step by step breakdown finally of replacing the shift forks. But before I get to dropping my engine, cracking my case and having a go at it I have a few questions.

Why are so many opposed to cracking the case in the first place?
Which fork handles 1-2? Im assuming its shift fork 1?
What kind of a cost am I looking at for doing all of this myself? (fluids, shift fork, etc)
Any advice on getting into this? or am I in way over my head for a winter project?

NoNothing wrote:Hey everyone,

So Im at the point where I want to get my 87 1000 on a track. The only issue I have is my shift from 1 to 2 sometimes misses under hard acceleration. Ive found through this forum that its cause is the shift fork being bent, and it will only get worse with time. Obviously this is an issue on a track as I'll be accelerating hard and then shifting.

I have the Haynes FZR600/750/1000 87-96 manual. So I have a step by step breakdown finally of replacing the shift forks. But before I get to dropping my engine, cracking my case and having a go at it I have a few questions.

Why are so many opposed to cracking the case in the first place?
Which fork handles 1-2? Im assuming its shift fork 1?
What kind of a cost am I looking at for doing all of this myself? (fluids, shift fork, etc)
Any advice on getting into this? or am I in way over my head for a winter project?

Hi,

try this :-
http://www.fzronline.com/forum/viewtopi ... +gear#p927

THIS HOW-TO is now in the WIKI

Thanks YG, I fail at using search I guess

NoNothing wrote:Thanks YG, I fail at using search I guess

I hate to tell you this but it did take me a while to sift thro what the seach engine found, which is why I put RageD's How-to in the WIKI as is for now. :-}

i won't say you are in over your head, but it IS quite an undertaking. if you're lucky and only need to replace shift forks it won't be too bad. i would suggest removing the complete engine from the bike as it will be much easier to get to the areas that need to be taken apart. total cost i would say you're looking at ~$100 or thereabouts, as i would also suggest replacing all shift forks, not just the damaged one. since you're in there you might as well replace them all. the prices may be different for a 1000, so i can't give you an exact amount. i ended up replacing my entire transmission, shift forks, clutch, etc and it cost me a few hundred dollars all said and done. my brother in law and i did all the work. as long as you're mechanically inclined the project should be fine for a winter project. good luck and let us know if you run into any issues

Hi, I have just gone through the same task, however whilst you are going that far into the cases, you may as well upgrade!
I replaced my old 5 speed with a complete 6 speed box out of a YZF750, your new 1st and 6th are almost identical to the old 1st and 5th, but you now have 4 close ratio gears to play with in the middle, I have done a couple of trackdays and the niggle I had was the 5 speed was holding the bike back due to the wide spread of gears, 6 is much better.
The upgrade is very simple:-
Remove all gear clusters, selector forks,selector drum, indent arm and oil spray bar.
Replace all of the above with a YZF750 transmission, you MUST change the oil spray bar as it has extra lube holes for the new gearing, swap/replace the bearing on the YZF750 output shaft (behind the rear sprocket) for the one off the old 5 speed shaft (narrower) for smaller casings (750 is larger around this bearing), once changed insert all gears as per 5 speed with all the parts that came with the 6 speed and your done.
Please see pics of various stages of rebuild below, unfortunately no close-ups of gear change.
PS you also have to remove the silencer/dampener from the inside of the sprocket cover as the YZF's shaft is approx 3mm longer and will foul the inside of the cover.
This mod has transformed my bike so I can recommend it fully.

Well I pulled the old baby apart and was very happy with the condition of all the parts apart from the 5speed box (knackered 2nd), decided to replace the chain driving the starter gear, will move cam timing (sprockets slotted by myself), match ports and general cleanup, getting away from the Black Block so thought I'd spruce her up a bit while she's apart, just waiting for starter chain before the assembly.
Just a few pic's of the tear apart with black/dirty parts and the new colour. Hope you like it.








Regards
Ozzyfzr