1 more '95 RF600R Back on the road! (replaceing 2nd gear & fork) pics inside!

[jcurrieta]

Heres my first journey into a bike... im mostly into cars but when my brother bought this project with the bike stuck in gear... we soon found it was a broken shift fork. So here's the story,,,,
(Also special thanks to this fourm, a downloadable Suzuki manual and to RF900fasteR "AKA Srxcitement" for email help!!)
Before: tearing it apart removing the body, wires, hoses, cables, tank, carbs, etc. to remove the engine.


Make sure to label wires:


removed the 2 rear mounts and the front ones and it drops down,,, we used a bike jack to drop it down:

[jcurrieta]

pan, oil filter housing, alt, starter, slutch and all takein off,,, and split case gears removed:


here is what we found:


so heres the used ebay gears and shift fork going back in:


testing to see if it moves thru the gears easy:


button it all up with the proper case sealant,,, not silicone.

[jcurrieta]

starting to hook everything back up,,, filling fluids, double and triple checking everything:




all body back on and running for the first time in 4yrs:

[Jetpilot5]

Nice job.  Most people, myself included, wouldn't be willing to get that deep into an engine.

[veefer800canuck]

I remember a magazine article where they took a katana 600 with (I believe?) the same air/oil cooled engine as the RF600 and swapped in a GSXR 1100 engine which was almost a 100% bolt in.

That would have been fun for this project I think.  :-)

But good work and happy riding to ya!

[Frankienuckles]

A friend of mine put a gsxr 750 motor in his katana 600 and it was almost just a "bolt in" engine swap.