Go Back   Horizons Unlimited - The HUBB > Technical, Bike forums > Yamaha Tech
striped gear lever striped gear lever
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 Andy Miller, UK, Taking a rest, Jokulsarlon, Iceland

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


Photo by Andy Miller, UK,
Taking a rest,
Jokulsarlon, Iceland



Reply
 
LinkBack Thread Tools Display Modes
  #1  
Old 28 Oct 2007
Contributing Member
Veteran HUBBer
  
Join Date: Mar 2003
Location: London,England
Posts: 358
striped gear lever
Hi the gear change lever and shaft on my XT 3AJ has completly worn the splines away.
I have managed to get it on tight but it wont last long (untill I fall off )
I think the engine has to be split to change the shaft but have been told by 2 mechanics that it is possible to remove most Yamaha gear change shafts from the clutch side.
Has any one done this or know if its possible?
Thanks
Reply With Quote
  #2  
Old 28 Oct 2007
Registered Users
Veteran HUBBer
  
Join Date: Jun 2007
Location: Ripley, Derbyshire
Posts: 373
If I understand this correctly then I can feel a Cambodian field repair coming on.


If you want a quick repair that you can take off later then fit the lever on the shaft and get a local guy to drill a hole right the way through it, as you should already have a hole in the lever just use that as a guide, then get a bolt or a piece of wire and make a split pin for it (just like your footpegs are connected to the bike).

If the lever is ok and the gear box is ok, then weld the damn thing on if all else fails, it will get you whatever major city you need to get to make a decent repair.

If I've misunderstood the question, then If you can get a picture of it to me that would be very helpful.
Reply With Quote
  #3  
Old 28 Oct 2007
Registered Users
Veteran HUBBer
  
Join Date: Jun 2007
Location: Ripley, Derbyshire
Posts: 373
I think I need to make it a little more clear after reading this again...

Imagine the Earth then imagine the North South Pole line that goes through it, that's what you need to do with the bolt, it shouldn't move then.
Reply With Quote
  #4  
Old 7 Nov 2007
Registered Users
Veteran HUBBer
  
Join Date: Aug 2007
Location: Sax, Spain
Posts: 901
yep i agree.....
Im with Judadredd on this one........ a small bolt drilled down through rhe middle was exactly what I had to do on a CG125 many many moons ago when i was but a skint young lad and on the dole..... them were the days WHEN YOU COULD GET A WORKING BIKE FOR A FIVER!
Reply With Quote
  #5  
Old 7 Nov 2007
Registered Users
Veteran HUBBer
  
Join Date: Jun 2007
Location: Ripley, Derbyshire
Posts: 373
Martyn,

Welcome to the Home of Cambodian Field Fixers, we don't need no stinking workshops the side of the road, some wire and tape and we are happy.

Oh the joys of owning your own motorcycle
Reply With Quote
  #6  
Old 7 Nov 2007
Registered Users
Veteran HUBBer
  
Join Date: Aug 2007
Location: Sax, Spain
Posts: 901
cambodian field fix my wiring loom...........please?
my wiring loom is banjaxed, knackered, demised, dead, proper poorly like.......

to the point of making my lights and any other electrical stuff not work intermittently, i dont care about the horn, i can shout, or the indicators i can wave an arm about... but at night it helps if the lights stay on when you live in the countryside and there are large ditches and cactuses or cactii ( both are correct) in abundance to run into...... I have rebuilt this bike from the ground up, just ordered another 160 euros worth of carburettor parts and a new fuel tap for her, but the wiring is driving me MAD!
all i want is a new loom and i will be happy. part number 2KF-82590-00 now discontinued.

any ideas?
Reply With Quote
  #7  
Old 7 Nov 2007
Registered Users
Veteran HUBBer
  
Join Date: Mar 2007
Location: UK
Posts: 4,343
Wiring loom
You're going to make one then, from scratch?
__________________
Dave
Reply With Quote
  #8  
Old 7 Nov 2007
Registered Users
Veteran HUBBer
  
Join Date: Aug 2007
Location: Sax, Spain
Posts: 901
may have to.........
not looking forward to it I can tell you.
Reply With Quote
  #9  
Old 8 Nov 2007
tomwest's Avatar
Registered Users
Veteran HUBBer
  
Join Date: Sep 2006
Location: At the moment:Zanzibar
Posts: 116
universal wire harness
Hi.

If you don´t care about your indicators and horn etc... and only want your lights to work why not just buy one of those universal set ups that you can buy for puting a set of extra lights on your car? they come with relays and connectors. then you just cut the cables to right lenght and run them trugh your original switches and dissconnect the battered original wires.

But makeing a new loom is acualy not as hard as it first might seem,as long as you have a wirediagram to look at and people have posted several good ones here in the past.

I have some laying around that I can send you if you trow me a pm with your E-mail.

cheers.

Tom
__________________
Places to be and things to do, see you all out there!!

Cheers.

Tom.
Reply With Quote
  #10  
Old 8 Nov 2007
Nigel Marx's Avatar
Super Moderator
Veteran HUBBer
  
Join Date: Oct 2000
Location: South Island, New Zealand
Posts: 798
Thumbs up Electric glue or Kiwi Cow Cockie repair?
I have welded up many gear levers, some two or three times over. If you need to get into the 'box with the lever welded on, careful use of a very small angle grinder or dremel will let you cut away the weld and still leave enough meat to weld up again.

The other fix I have used when I was a cow cockie goes thusly:

1: Remove gear lever and take out bolt

2: Put clamp end of lever in a vice and pinch the clamp up until the gap is shut.

3: Cut down gap with hacksaw thus widening the gap by about 2mm when released out of the vice (The last little bit is hard to cut as the vice will pull down onto the saw blade. I cut those edges out with the lever blade in the vice, not clamp)

4: Drill out the old bolt hole thread so you can fit a same sized, high-tensile bolt right through.

5: Tighten up the high-tensile nut and bolt really tight and this will hold for quite a while.

Regards

Nigel in NZ
__________________
The mouth of a perfectly contented man is filled with . -- 2200 BC Egyptian inscription
Last edited by Nigel Marx; 8 Nov 2007 at 21:37. Reason: Spelig mistaks
Reply With Quote
  #11  
Old 10 Nov 2007
Registered Users
New on the HUBB
  
Join Date: Nov 2007
Location: Somerset, UK
Posts: 3
Gear lever repair
Another method of repairing stripped gear lever splines is to fit the gear lever and tighten the bolt to hold it in place then drill into the end of the gearchange lever shaft and gear lever. This effectively creates a new master spline, drill the hole slightly smaller than the bolt or rod that you are going to insert (I've used an m 5 bolt before) then undo the clamp bolt, insert the short bolt or rod, if necessary tap it home with SMALL hammer then re-tighten the clamp bolt. I did this repair on my '77' XT500 3 years ago and it hasn't moved since. If you need a photo to explain better, please e-mail and I'll send you one. Ed.
Reply With Quote
Reply

« 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
XT600e Gear Lever mbishop Yamaha Tech 11 1 Nov 2010 08:34
Mesh Riding Gear - looking for opinions... davidmc Camping Equipment and all Clothing 22 4 Sep 2005 17:24
leaving gear safe with the bike fireboomer TRAVEL Hints and Tips 3 3 Oct 2004 22:02
Gear Lever - Fiche? & Any uprated ones available? mbishop Yamaha Tech 1 18 Mar 2003 15:42
Is my gear too basic? Mel D Photo Forum 4 16 Nov 2002 18:03

 
 

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

ALL Dates subject to change.

2025 Confirmed Events:

  • Virginia: April 24-27 2025
  • Queensland is back! May 2-4 2025
  • Germany Summer: May 29-June 1 2025
  • CanWest: July 10-13 2025
  • Switzerland: Date TBC
  • Ecuador: Date TBC
  • Romania: Date TBC
  • Austria: Sept. 11-14
  • California: September 18-21
  • France: September 19-21 2025
  • Germany Autumn: Oct 30-Nov 2 2025

Add yourself to the Updates List for each event!

Questions about an event? Ask here

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...

Adventurous Bikers – We've got all your Hygiene & Protection needs SORTED! Powdered Hair & Body Wash, Moisturising Cream Insect Repellent, and Moisturising Cream Sunscreen SPF50. ESSENTIAL | CONVENIENT | FUNCTIONAL.

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 10:47.

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