Go Back   Horizons Unlimited - The HUBB > Technical, Bike forums > Yamaha Tech
replacing my 5th gear again! replacing my 5th gear again!
Register FAQ Calendar Today's Posts
Yamaha Tech Originally the Yamaha XT600 Tech Forum, due to demand it now includes all Yamaha's technical / mechanical / repair / preparation questions.
Photo by Michael Jordan, enjoying a meal at sunset, Zangskar Valley, India

I haven't been everywhere...
but it's on my list!


Photo by Michael Jordan
enjoying a meal at sunset,
Zangskar Valley, India



Reply
Page 2 of 2 1 2
 
LinkBack Thread Tools Display Modes
  #16  
Old 15 Nov 2009
wolfzero's Avatar
Registered Users
Veteran HUBBer
  
Join Date: May 2009
Location: uk
Posts: 434
my 96 xt600e gearbox was in perfect condition when i stripped it down because of a different mechanical failure

there has been a few crankshaft woodruff key failures on the later 4pt models
__________________
XT 630 SUPERMOTO

GSXR750L KMX200

RF900 & GSX400X Impulse Projects
3.9 V8 Rangerover
Reply With Quote
  #17  
Old 15 Nov 2009
Registered Users
Veteran HUBBer
  
Join Date: Dec 2008
Location: Denmark
Posts: 1,417
my 2003 xt600e has done just around 72.000km with no enginework.

I've always heard it only was the early models.
Reply With Quote
  #18  
Old 15 Nov 2009
G600's Avatar
Registered Users
Veteran HUBBer
  
Join Date: May 2009
Posts: 235
Pigford, yep, wondering if I should tear into the TT’s engine and take a look. Not now but maybe next winter. I think the new oil line that squirts oil directly on the gearbox was introduced in 1990, in the 3TB model. So I am curious if this new oil line eliminated the fifth gear problems.

Wolfzero… thanks. I saw the pictures of the engie… Ugly stuff.

Jens, 72K? No engine work? Not even a new clutch? Wow… and I have seen in your pictures that you really use the bike… You got to love these bikes. My KTM520 lasted maybe 10K km, before the gearbox broke. It had some crankshaft problems also…
__________________
----------
Yamaha XT600E '01, Honda XR400 '03, Yamaha XT550 '83
Reply With Quote
  #19  
Old 15 Nov 2009
Registered Users
Veteran HUBBer
  
Join Date: Dec 2008
Location: Denmark
Posts: 1,417
I bought it with 51xxxkm on last summer, and now its just under 72.000, so it has been used well =) But i do change oil often, and change the filter everytime. Thats a good start.

Its been riding all winters (and you can tell) but the engine is going strong, without any weird sounds, and I've even tuned it up a bit. Foamfilter, opened airbox, oversize headers and laser produro exhaust. I guess the foamfilter is adding to make the bike more reliable, as it should let less dirt through.

A guy here from Denmark bought a xt600 in the mid 80's as far as i recall, he did 250.000 of commuter km's before the piston got stock. New piston, bored and honed cylinder new bearings and rod, and cam chain and he's done 35.000km since. It costed him under 300$ in parts.

Thats what theese bikes are all about. The wont wheelie in 3rd or 4th like a pumped ktm, husqvarne og anything like that, and they are big and heavy, but they will keep on going.

This pic from todays ride says it all:

http://peecee.dk/uploads/112009/DSC00289.JPG
Reply With Quote
  #20  
Old 16 Nov 2009
Registered Users
Veteran HUBBer
  
Join Date: Nov 2009
Location: christchurch newzealand
Posts: 384
Mine is a 2002 600e and the gears are on their way out,anyone know who does good replacement gear cogs apart from yamaha that is!
Reply With Quote
  #21  
Old 16 Nov 2009
G600's Avatar
Registered Users
Veteran HUBBer
  
Join Date: May 2009
Posts: 235
Kenymact, sorry to hear. I have not heard of anyone supplying gears except Yamaha.

But this is new info in this thread. Since you have a 2002, obviously the “new” oil line (squirting oil on the gearbox) did not fix the problem.
__________________
----------
Yamaha XT600E '01, Honda XR400 '03, Yamaha XT550 '83
Reply With Quote
  #22  
Old 17 Nov 2009
jim jim is offline
Gold Member
Veteran HUBBer
  
Join Date: Aug 2003
Location: Cape Town South Africa
Posts: 222
The Yamaha gears are not actually as expensive as you may think - I paid about R1100 for the 2 which is around 85 Euro. This is the cost in South Africa- maybe you guys get ripped harder than we do...
__________________
"If we don't find something good at least we will find something new." Voltaire
Reply With Quote
  #23  
Old 18 Nov 2009
Registered Users
Veteran HUBBer
  
Join Date: Aug 2009
Location: Dorset UK
Posts: 395
Quote:
Originally Posted by jim View Post
The Yamaha gears are not actually as expensive as you may think - I paid about R1100 for the 2 which is around 85 Euro. This is the cost in South Africa- maybe you guys get ripped harder than we do...

I think Kenymact was after "non-Yam" gears so they last longer - more of an UPGRADE
Reply With Quote
  #24  
Old 18 Nov 2009
Registered Users
Veteran HUBBer
  
Join Date: Nov 2009
Location: christchurch newzealand
Posts: 384
Any gears would be good at the moment,being new to yam xt series I,m not sure how the engine s are identified,or whet year model is which,I still need to find my eng id number but don,t know where to look as I have no manual yet.

I,ve just ordered a complete overhaul gasket set from e bay,I will order a wiseco oversize piston next and start by finding some special tools I might need like the one that holds the crank from turning,looks like a pair of mole grips with long arms and two dowels for holding stuff.......

Not sure how big I should go on the oversize piston so if any one has done it before drop me a line as all help is welcome.

I,m looking on e bay for some gear clusters but as mine is a 2002 600e model I don,t think they come up very often but if any one has sourced some from somewhere could they let me know....
Reply With Quote
  #25  
Old 19 Nov 2009
G600's Avatar
Registered Users
Veteran HUBBer
  
Join Date: May 2009
Posts: 235
Kenymact if you have the time, I think many guys on the HUBB would be most interested in a short description and some pictures of the rebuild.

Btw, how many KM do you have on the XT?
__________________
----------
Yamaha XT600E '01, Honda XR400 '03, Yamaha XT550 '83
Reply With Quote
  #26  
Old 19 Nov 2009
wolfzero's Avatar
Registered Users
Veteran HUBBer
  
Join Date: May 2009
Location: uk
Posts: 434
[quote=kenymact;264654]
Not sure how big I should go on the oversize piston so if any one has done it before drop me a line as all help is welcome.
quote]

piston maximum is dictated by barrel liner size if you don't change the barrel liner and enlarge the crank case aperture 3mm oversize is the max without new liner and crankcase mods which gives you a piston of 98mm and a capacity of 635 ish cc

i've got a high comp 98mm in my supermoto xt 600 see the thread of the same name for details
__________________
XT 630 SUPERMOTO

GSXR750L KMX200

RF900 & GSX400X Impulse Projects
3.9 V8 Rangerover
Reply With Quote
  #27  
Old 19 Nov 2009
Registered Users
Veteran HUBBer
  
Join Date: Nov 2009
Location: christchurch newzealand
Posts: 384
Hi G600,it had 73000 kms when I picked it up but put anothe 800 riding home from the North Island of newzealand to my house in christchurch which is in the south island...
Reply With Quote
Reply
Page 2 of 2 1 2

« Previous Thread | Next Thread »

Currently Active Users Viewing This Thread: 1 (0 Registered Users and/or Members and 1 guests)
 

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts
BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are On
Pingbacks are On
Refbacks are On

Similar Threads
Thread Thread Starter Forum Replies Last Post
Replacing exhaust-bracket question?? doc44 Yamaha Tech 5 19 Nov 2009 13:53
Replacing plastic swing arm bushes Mark Yamaha Tech 4 1 May 2009 09:30
Replacing gaskets lysander Yamaha Tech 6 22 Jul 2008 15:21
replacing forks,xtz futronix Yamaha Tech 0 18 Apr 2006 14:18
Replacing a Gasket OXXT Yamaha Tech 5 18 Jan 2003 06:44

 
 

Announcements

Thinking about traveling? Not sure about the whole thing? Watch the HU Achievable Dream Video Trailers and then get ALL the information you need to get inspired and learn how to travel anywhere in the world!

Have YOU ever wondered who has ridden around the world? We did too - and now here's the list of Circumnavigators!
Check it out now, and add your information if we didn't find you.

Next HU Eventscalendar

HU Event and other updates on the HUBB Forum "Traveller's Advisories" thread.
ALL Dates subject to change.

2024:

2025:

  • Queensland is back! May 2-4 2025!

Add yourself to the Updates List for each event!

Questions about an event? Ask here

HUBBUK: info

See all event details

 
World's most listened to Adventure Motorbike Show!
Check the RAW segments; Grant, your HU host is on every month!
Episodes below to listen to while you, err, pretend to do something or other...

2020 Edition of Chris Scott's Adventure Motorcycling Handbook.

2020 Edition of Chris Scott's Adventure Motorcycling Handbook.

"Ultimate global guide for red-blooded bikers planning overseas exploration. Covers choice & preparation of best bike, shipping overseas, baggage design, riding techniques, travel health, visas, documentation, safety and useful addresses." Recommended. (Grant)



Ripcord Rescue Travel Insurance.

Ripcord Rescue Travel Insurance™ combines into a single integrated program the best evacuation and rescue with the premier travel insurance coverages designed for adventurers.

Led by special operations veterans, Stanford Medicine affiliated physicians, paramedics and other travel experts, Ripcord is perfect for adventure seekers, climbers, skiers, sports enthusiasts, hunters, international travelers, humanitarian efforts, expeditions and more.

Ripcord travel protection is now available for ALL nationalities, and travel is covered on motorcycles of all sizes!


 

What others say about HU...

"This site is the BIBLE for international bike travelers." Greg, Australia

"Thank you! The web site, The travels, The insight, The inspiration, Everything, just thanks." Colin, UK

"My friend and I are planning a trip from Singapore to England... We found (the HU) site invaluable as an aid to planning and have based a lot of our purchases (bikes, riding gear, etc.) on what we have learned from this site." Phil, Australia

"I for one always had an adventurous spirit, but you and Susan lit the fire for my trip and I'll be forever grateful for what you two do to inspire others to just do it." Brent, USA

"Your website is a mecca of valuable information and the (video) series is informative, entertaining, and inspiring!" Jennifer, Canada

"Your worldwide organisation and events are the Go To places to for all serious touring and aspiring touring bikers." Trevor, South Africa

"This is the answer to all my questions." Haydn, Australia

"Keep going the excellent work you are doing for Horizons Unlimited - I love it!" Thomas, Germany

Lots more comments here!



Five books by Graham Field!

Diaries of a compulsive traveller
by Graham Field
Book, eBook, Audiobook

"A compelling, honest, inspiring and entertaining writing style with a built-in feel-good factor" Get them NOW from the authors' website and Amazon.com, Amazon.ca, Amazon.co.uk.



Back Road Map Books and Backroad GPS Maps for all of Canada - a must have!

Your ad could be here, on EVERY page of the HUBB, or the whole website, or as many as you like!

New to Horizons Unlimited?

New to motorcycle travelling? New to the HU site? Confused? Too many options? It's really very simple - just 4 easy steps!

Horizons Unlimited was founded in 1997 by Grant and Susan Johnson following their journey around the world on a BMW R80G/S.

Susan and Grant Johnson Read more about Grant & Susan's story

Membership - help keep us going!

Horizons Unlimited is not a big multi-national company, just two people who love motorcycle travel and have grown what started as a hobby in 1997 into a full time job (usually 8-10 hours per day and 7 days a week) and a labour of love. To keep it going and a roof over our heads, we run events all over the world with the help of volunteers; we sell inspirational and informative DVDs; we have a few selected advertisers; and we make a small amount from memberships.

You don't have to be a Member to come to an HU meeting, access the website, or ask questions on the HUBB. What you get for your membership contribution is our sincere gratitude, good karma and knowing that you're helping to keep the motorcycle travel dream alive. Contributing Members and Gold Members do get additional features on the HUBB. Here's a list of all the Member benefits on the HUBB.



All times are GMT +1. The time now is 16:51.

Contact Us - Horizons Unlimited Motorcycle Travellers Website - Archive - Privacy Statement - Top