Here is a pic of the front sprocket

I am looking at grinding off the welds and weld a new proper socket on

whoever did that welding should have his hands cut off.


Why do you want to repeat the same disaster and not repair properly?


Even if you put a new output seal the welding heat is going to burn the seal lips on the shat for sure, it's an oil leak just waiting to happen.


take the engine apart, send the shaft to a pro to have a threaded part welded to it and this will let you change sprockets also in the future.


shaft is going to loose plenty of it's heat treatment/strenght so obviously best would be to get a used one.



what you want to repeat is such a bodge that i have no words for it.

Only reason for welding a new 15 on the front is so I dont have to crack the case. I'm 1500 into a $400 bike. I'd rather weld a new sprocket on....very carefully. And run it for 6montsh till I can buy an electric start motor to swap in.

But the tooth count explains why it will wheelie in 4 gears

- sounds rude but generally true. doing such thing primarily indicates how one dislikes a bike, i.e. doesn't deserves to ride it, i.e, no need of hands : )

Is there any possible 12-teethed sprocket which fits on xt600's?
point is that despite that heat damage during welding is somehow preventable, you will be lucky if after removal of the old sprocket you will have shaft end usable for attaching new sprocket - at least from the point of view of centering or perpendicularity..

"imho" is related to the upper part of this post but no further of this point - short term, and sometimes even "non-long term" solutions are reasonably expensive at the end...

carefully would mean in my book taking an hour break for every ten seconds of welding so heat gets dissipated.

my guess is that the thing got welded on because the splines on shaft got mangled, so it will need to be a pretty hefty weld to pass the drive torque, not just keep the thing in place.



Good luck

https://youtu.be/RtLU87Oar6I


https://youtu.be/OxG1sw-0Tac


First vid is orange wire to coil from cdi. That is the highest reading I could get.

Second is white wire off stator. Both wires showed same

As you can imagine...no spark..even with new coil.

Stator showed 25.7 on red wire. Pick up coils showed 120-115ohms. Right where they should be

It was very hard to start before...so I'm thinking new cdi

The old XT cdi actually went out quite often and was a known issue by Yamaha. They even put out test specs for the cdi, which is pretty much unheard of to have test specs for a cdi. Even then the test wasn't always conclusive. the coil on a bike rarely ever goes out. It will be your stator pickup/pulsar or the source coil, or it will be the CDI. I have a performance CDI I would sell if interested. never installed it. Ended up converting to e start and TCI right after I bought it years ago. Been sitting in my tool box ever since.

For your seat cover, there is a Chinese company on ebay that sells an exact replica for the XT600 seat cover. I purchase and installed a couple years ago and it's been awesome!

I may be interested in the cdi. Can you PM me info and price?