94 SUZUKI RF600R needs 2nd gear repaired. Is it possible to split the case without removing cylinders and heads?

SOURCE: No second gear

Sounds like a bent shift fork to me. Not wanting to go into or between gears plus popping out of 2nd and making a knocking noise are classic symptoms.

Please rate this solution as a " FixYa " after the repair. Thanks!

SOURCE: timing specs for 94 suzuki rf600r

shop manual page 16 and 22

SOURCE: I have a 1970 Yamaha XS650 that pops out of 1st gear.

No,You will need to split it to repair.

gavin jones

• 1508 Answers
• Posted on Mar 16, 2011

SOURCE: Hi. Suzuki rf600r 1993.

a 93 model is likely to need a chain and tensioner, if you undo the tensioner mounting bolts it should spring out 10-15mm

mxtras

• 194 Answers
• Posted on Apr 29, 2011

SOURCE: I have a 1982 Suzuki

Here's the easiest way:

Put the head bolts back on snug. Put the spark plug back in snug. Put the cylinder base nuts back on but leave them about 1/4" away from seat. Now give the kickstarter a swift hit down - you can do this by hand. Repeat until the cylinder pops up. Now, loosen the head nuts and repeat.

This is the easiest way to remove a cylinder.

Hope this helps.

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