gearbox gear removal
 

So I ,ve split the crankcases and now need to replace the 5th gears,.....one comes off easy but I think I need to pull the other from the shaft..does any one know which puller to use and do I need to press the new one back on?...answers on a postcard to.......

Just done it tonight...tok me 15 minutes,triple leg gear puller ...tightened it up and screwed it out...piece of cake.....now the hard part will be to squeeze the new one on...

Hi Kenymact,how much of a pain is it to strip down an XT engine?I have been offered an XT600E with gearbox trouble,not sure quite what is wrong with it.I am pretty handy with the spanners,just never been inside an XT before.

Hi Trophy Dave......I,ve never done anything like this before but a good confidence booster is a you tube video called yamaha srx 600 engine disassembly YouTube - Yamaha SRX 600 Engine Disassembly I Its the same engine as ours just about and I watched it so much it looked easy....

So far the only trouble I had was removing the clutch basket which you need to do with a pnuematic or battery rattle gun.I mad a round plate with three holes in it topull the rotor off and used a 3 leg puller to remove the gears...so so good and no big problems.

Bought a complete gasket set from e bay and wil ordermy gears and tab washers from the dealer.

I just got my head round it and got right into it......I sort of kept putting it off untill the winter was coming and now I,m halfway through I,m looking forward to putting it back together again...very daunting at first but once into it it becomes quite interesting and a challenge too......

Go for it.......its not so hard..:thumbup1:

stick the shaft in the freezer and the new gear in the oven and it will squeeze on really easy also works well on fitting new headstock bearings too :thumbup1:

Cheers wolfzero, I have access to dry ice and an oven at work so when the new ones come I ll do it at work on the press......

O.K. thanks.The bike belongs to a mate who has owned it for many years so I am not too sure if he will sell it,we will see.:mchappy: