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2000 Honda CBR600F Doesn’t stay in 3rd gear Symptoms gear gearbox not selecting third gear or poppin

2000 Honda CBR600F

Doesn’t stay in 3rd gear

Symptoms gear gearbox not selecting third gear or popping out of third gear,

in order to understand why this Motorcycle will not select or stay in third gear we needed to remove the engine and also the sump to gain access to the selector drum when this was removed we then gained access to the gear selector forks, so we could

Evaluate what condition they would be in.



As you can see the selector fork in the photo is extremely worn, we can use vernier or micrometers to measure the specific parts of the selector forks, with a visual inspection you can see in the blue circle bluing of the metal and a lip where material has worn away, something more integral has worn in order for the gear selector to of become this bad, in order to find out the level of damage we would need to strip the entire engine down to inspect all the gears, bushes spacers and gear dogs,



This Photo shows the measurements in MM (millimetres) the service limit for this part (which is a selector fork)is 5.9mm on the paws shown in blue the selector paws this is is under that limit and therefore must be changed




This is the inside diameter (ID) or selector fork Bore the service limit on this part is 12.03mm so we can see this is also out of tolerance.




In this picture is the selector fork shaft the measurement we are looking for is between 11.957-11.968mm we only have 11.93mm so this part is also out of tolerance, what we can conclude is that the gearbox in order to be working fully and without any issues would require a full strip and rebuild.


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