Re: Here is what you need to fix the 2000 750 2nd gear
I've just taken my 750Y out for a blast having just completed the rebuild for the 2nd gear issue. All good, no leaks, thank f**k.
I replaced 2nd & 6th gears, shaft, 2 forks, clutch pushrod & seal (just in case) and o rings, water pump seal, gaskets etc. One fork showed the classic signs of wear but did not seem bent. IMO the shaft did not need replacing but since I'd bought the part it went in. I couldn't see any difference (apart from wear) in the old and the new fork.
I'm not sure where the 'play' came from that caused the gears to diengage, maybe the selector drum should be changed. Seems OK at the moment.
A couple of tips for anyone else doing the job.
#1 Jack up the front of the bike by at least 4in, it makes getting the engine out much easier.
#2 Fabricate an open wooden box around the sump for the trolley jack, it makes the engine much more stable for reassembly than balancing on the drain plug.
#3 When replacing the transmission housing on the lower crankcase it is easier to have the engine completely upside down and chocked securely (make sure you don't put all the weight on the magnesium parts on the cam cover though), so that the forks in the transmission case hang upside down making it easier to locate them on the gear shafts. I practised this procedure a number of times before spreading the gasket bond on and going for it.
Otherwise, its as per the manual and this forum is a great help. Just go steady and keep it clean.