Need some direction...

[contact_jcj]

I have a 92 fzr 600. A couple of weeks ago I was not able to start my bike. I was able to push start it in order to get to work. I was not able to push start it in order to get home. The battery was holding a charge, but only had 92 cold cranking amps so I replaced it, but this did not solve the problem. I checked for voltage at the starter solenoid, and the starter itself, and this was ok. I also removed the starter and took it to a parts store and it tested ok under those conditions. When I turn the key to the on position the lights come on, and when I turn the main switch to the run position there is a click from the seat area. When I engage the ignition switch the lights go off and there is a series of clicking noises from the solenoid, amd the bike doen not crank over and start. I went through the steps for the safety system in the online manual, but I do not think this is the problem. I left the kick stand switch disconnected as a test, and nothing on the bike would even register as being active. I also followed some testing posts on this forum(DonTZ125), such as the coils, and this was also ok. I tested the continuity of the Ignitor, and this passed muster as well. I also tested the main relay, per the online manual, and it seemed to be ok but I got a replacement anyway, and this did not help. At every step during the troubleshooting, I have tried to push start it, but can't get the engine to turn over. The fuses are not burned out. There is a large ground wire that goes from the battery negative terminal to some kind of ground bus (?), and this had come loose. I fixed this but it did not have any positive affect either. I removed the starter again, left the power cable connected and grounded it to the bike, and the starter motor was spinning when it was away from the engine housing. Is there some way I can try to determine if the engine has seized??? I should be able to push start it, and this makes me concerned that something serious might be wrong. I am looking for suggestions on steps I can follow to see if the problem is internal. Any and all comments will be welcome...thank you.

[97fzrnoob]

As far as testing the motor out, put in neutral, pull the plugs and stator cover off, and use the bolt on the end of the crank to turn it. If it doesn't budge, it may be seized or bent valves, it should rotate fairly easily so don't force anything.. Also check the starter gears behind the peanut cover to make sure they're not binding or anything.

[contact_jcj]

I took the peanut cover off and this is what I found. The gears were bound up so badly that I had to use a screwdriver to get them moving, and there were a few missing from the largest one. Once I got it passed the damged part, then I was able to move them by hand. Something obviously happened to either cause the damage or there was just some kind of failure on the components. I was able to remove the top port, that is connected directly to the starter, and I was able to remove the second one in line. I tried to engage the starter without the cover in place, but you can see the support points built into the cover for the posts of each gear that have to hold it in place to work right. Any input about this particular problem? If I need to replace it, can I just get the large gear by itself? Is the round piece holding everything in place just for these gears, or is it holding other components in place also?

[nicrod]

YIKES!
you have a problem there ...
I dont know what would cause that, but replace that shit!

[97fzrnoob]

Well at least you can rule out the motor now. My guess as far as how it happened is, when you were able to push start it, the gears may have been stuck out and when it fired up it trashed 'em. Hope you can find a member here with some or a good set on Ebay cause those gears are expensive new on both bikebandit and ronayers. On the parts fiche, they use the same part number for the FZR and YZF600r's. So ya may have more luck finding em from a YZF, and are the support holes in the peanut cover good? http://www.ebay.com/itm/2000-YAMAHA-YZF ... fb&vxp=mtr best deal so far

[contact_jcj]

Thank you for the link, that was helpful. The supports inside of the cover are not damaged. The first part turns counter clockwise, and the rest of the assembly does also. I am able to move the entire assembly easily by hand with a 14 mm wrench on the bolt in the center. I am also able to turn the bolt in a clock wise manner, and the round black piece moves by itself without engaging the gears. I was also able to loosen the 3 allen bolts on there. How exactly am I supposed to get the bottom apart? Is it pressed into place like some bearing are ( which are under pressure ) ? And, what is it connected to?

[97fzrnoob]

You will need to borrow/rent or buy a 3-leg puller to get the gear assy. apart. I think there is an online manual that shows exactly what to do (in the wiki maybe). I can scan the page from my repair manual that shows what to do if needed.

[contact_jcj]

That would be helpful. My email address is contact_john_c_jones@yahoo.com

I contacted the seller of the item you found, but he has not gotten back with me, so I started looking again today.


This looks exactly like what is on there now.

http://www.ebay.com/itm/1989-1998-Yamah ... 4c&vxp=mtr

[97fzrnoob]

I sent the scans to your email and a link for an online service manual.

[contact_jcj]

I fixed my bike a few weeks ago. If someone needs help with this particular task, I can offer the scanned pages from the repair manual that another forum member provided to me.

[HybridSport600]

WOW! what a mess, sorry to see this man, I wanted to remind you to use some blue locktite on those bolts, blue is best, holds strong and will allow easier release than the red will. Also look at all the bearings in there for signs of shredding, looks to me that a foreign piece of metal loged and broke some teeth off and a few more when forcing it to start. I repaired a 96 that had done a similiar break, but was the center idle gear instead of the crank gear...anyhoo, sorry to see this for anyone!! Id change the oil as well and look for metal bits, better safe than sorry..