Problems with 2nd gear

[tuni]

Hi
I just returned from my trip to Alps wtih my my wife. I was forced to return sooner beacuse of odd sound from the gear box.

When I was driving down steep alps roads with 2nd gear and giving gas again after engine braking I could hear pretty bad mechanical sound from gearbox. After that I decided to return home asap and also changed the engine oil instalty to see if there is any metal found in the oil but nothing was found.
On my return trip back same sound could be heard with 2nd gear even in cities so I tried to avoid the 2nd gear as much as possible. Otherwise bike was working OK.

Bike is -95 900 Div. and driven 80tkm which is a disapointment for me because my old XJ650 did 160tkm without any problem.

Any similar experiences or ideas what is the reason?
My estimation is that gear change fork shaft or a fork is bent or some spring is broken. I am planning to take the engine apart or during winter.

[General Gman]

I fear you have diagnosed the problem correctly and will be elbow deep in gearbox parts come wintertime

[tuni]

I am almost done with the reparation. I took off the engine, disassembled cylinder head and cylnders, took off oil sump and started to check what is the problem.
Everyhting looked fine, except the gear change drum was moving axially. Therfore I took off the left cover and found out that two fastening screws were loose!!!!!! That was the problem! That could have been fixed even on Alps in few hours.
I did not see any marks of any glue on the screws. Maybe some quality error on a first production series. Body numebr is 00016.

Well anyway it was nice to see how good the engine looked inside. Almost no wear at all on cylinders and pistons. Gearbox looked like new and the engine has done 85tkm!!!

Local Yamaha importer told that I was the first one to buy piston rings and cylinder gaskets from them. I can believe that. This engine seems to last forever.

[CD]

I had the cam cover off my D900 (48K miles) this last week to get it stove enamelled*. The inside was so clean it looked like new. Annoyingly, it will have to come off again at Easter as I couldn't find my feeler gauges to check the clearances. :-( At least, all of the cams had an unpolished area so the valves are all closing.

* I'd sent it for powder coating, but the enamellers told me properly done stove enamel is much better on aluminium.

[neilmud Lord Protector]

Get a fazer only use 2nd if you want to see a ton ;D

Neil

Glad to see its ok now another Divi lives to fight another day.

[doyle]

Many thanks to the OP for this thread.

Info like this is just one reason (of many) that makes this forum so valuable.