Gear changes

Hi all

I have just picked up my 1991 XJ600 with 40,000 miles on the clock.

It seems to run pretty well so far, apart from one thing. The gear changes.

The gear lever is pretty "mushy" feeling and going up into neutral is very hard. It also seems as though the lever is a little bit higher than I would like as its a bit far from the top of my boot, so I have to strain to shift up, if that makes any sense?

It appears as though there is a linkage on this gear change lever, so I can assume that some aspect of this is worn, can anybody tell me if there are any common bits that wear?


Also the front brakes are a bit mushy, the back is great and has good feel. The front is odd, the lever is mushy, and you pull the lever, nothing, pull it a bit more, nothing, but more LOTS of braking .... Might need to pull that apart.

Thanks all

 

The shifting issue is likely due to a mis-adjusted clutch, and/or the previous owner was running the wrong oil. You need to use motorcycle-specific oil these days.

The linkage can be adjusted. It may have been mis-adjusted as well.

You will need to REBUILD the front and rear brakes; anything less is simply too dangerous.

 

Cool, I will do an oil change soon as its new to me, no idea when he last did it.

I will have a look through the service manual if it mentions adjusting the linkage.

Many thanks

 

Take a close look at how the linkage is positioned on the shafts. If the lever position is as extreme as you say, the previous owner may have had the linkage off and got it back on one spline off.

Yamaha probably recommends 20W40 for that bike; 20W50 is fine. Castrol 4T is universally available.

In regard to the brakes: I was serious. The factory-recommended life span of the caliper and master cylinder seals was two years; the brake lines four years. Granted, that's a bit conservative; but 20+ years is well beyond any designed-in safety margin. You can't see rotting brake lines, they deteriorate from the inside out and all you can see is the rubber outer sheath.

The symptoms you're experiencing with the front brake are consistent with master cylinder/caliper seal issues, and could lead to an unexpected front wheel lockup.

 

I will have a look at the spline location, is there a alignment mark I should be looking at? Otherwise I will just try swapping one spline position and see if its any better.

I do intend on doing the brakes dont worry.

Apart from caliper seals and new brake lines, what else should I be looking at in the brake system.

 

Master cylinder seals, new pads all the way around, and NEW crush washers (one on each side of every "banjo.") Take the opportunity to upgrade to stainless lines, it's a huge improvement over stock.

I looked on my 550, and it doesn't have an alignment "dot" but the shifter is just attached straight to the shaft. My 650 Seca has a linkage, but the bike is buried right now and I can't see the left side.

Sometimes there's an alignment "dot" on the shaft that corresponds to a mark (or the clamp split) on the lever.

 

It just had new pads all around, but I will order new pads and crush washers now.

Also have a spare braided kit lying around, should be more than enough to replace the old one.

Many thanks for looking. I have adjusted the linkgage a bit so will see what its like on the way to work tomorrow.

 

Curious to know how it got past the M.O.T. with dodgey brakes. Regardless of whether it's got new pads all around, if the brakes are "mushy" you should park it til it's well and truly sorted. A good back brake is not enough.

 

My 650 Maxim (17k miles when purchased) had shifting issues until after two oil changes. I use the cheapest Walmart Super Tech 20W50. No additives and inexpensive. The 650 Maxim loves this oil.

 

I think the brake situation has been taken a bit too literally. The brakes aren't BAD, just not great. I have had other bikes with worse brakes.

Either way, I have new lines, caliper seals and MC seals on their way, so will be rebuilding them soon.

On the MOT they test the brake power on a brake stand. This defo has enough power to pass that. My super dreams brakes where ridiculously poor and that passed!

 

I have noticed as its being used my shifting is getting much better. I have adjusted the linkage quite a bit, and put a thicker washer on to take up the slop. I wonder if the previous owner hadn't ridden it in a long time. I have some new oil and stuff coming soon so that may help it even more.