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Yamaha Tech Originally the Yamaha XT600 Tech Forum, due to demand it now includes all Yamaha's technical / mechanical / repair / preparation questions.
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  #1  
Old 15 Feb 2011
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xt600 primary drive gear
have been reading up posts on this prob( primary drive gear -woodruff key ), i have a noise that sounds like the starter motor staying engaged ( i have already checked the starter and its ok ), the noise stops in 2/3 minutes, but i have traced the sound and put my hand on engine case by the oil filter and the noise comming from there, also i am getting a knock that i hope and think is a kink in my chain, the chain is an o ring thats done 10,000miles ( i have a chain oiler fitted ) chain and sprockets due to be changed .

so, is this a big/hard job to get at, and if necessary repair/replace, or is it a job for a mecanic

i am not a mecanic, i have done my own services oil/filters/plug and tappets, done brakes, tyres/punctures.........but only in the last 8mths.


i have the parts manual and workshop manual off the hubb links.

The bike is Xt600e reg 2007, I bought it 10mths ago with 1,700miles on clock, it now has 15,000miles, oil/filters replaced every 4,000miles.

any help would be appreciated.


denny
Last edited by diehard; 15 Feb 2011 at 14:28.
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  #2  
Old 18 Feb 2011
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It's not overly difficult. You remove the RHS foot peg/brake assembly. Remove the clutch cover (you will need a new gasket) and your there! Stick a copper washer in the gears to stop them turning so you can undo the nut. You will be fine. The key is 7mm square so if you can't get the Yamaha part you can find an alternate key steel (SAE 4140) and cut it to size.

Regards, Dave
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  #3  
Old 19 Feb 2011
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I think this is starting to happen to mine
what actually happens to the key ? does it break, rub , come loose ?????
thanks for heads up
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Old 20 Feb 2011
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Quote:
Originally Posted by Dazzle View Post
I think this is starting to happen to mine
what actually happens to the key ? does it break, rub , come loose ?????
thanks for heads up

Mine almost sheared off. Allowed enough movement to make a strange noise when backing off the power in lower gears.

Regards, Dave
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  #5  
Old 20 Feb 2011
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Mine only occasionally does it for 10-20 seconds on a cold start up
will put it on the things to do list
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Old 21 Feb 2011
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Quote:
Originally Posted by diehard View Post
have been reading up posts on this prob( primary drive gear -woodruff key ), i have a noise that sounds like the starter motor staying engaged ( i have already checked the starter and its ok ), the noise stops in 2/3 minutes, ..........
It's been quite a while since I had probs with mine but the sound was a constant knocking as the gear teeth backlashed (so a bit like a starter motor yes) but the sound does not go away it gets worse. What you describe sounds suspiciously like little end knock. The sound tends to deaden as the metals expand to fit and the oil lubrication comes into play creating a liquid bearing.

The woodriff key tends to shear (my experience) if you labour the engine at low revs excessively. But here's to hoping that your diagnosis is correct, because it is an easy fix.
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Old 21 Feb 2011
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still checking
took crank case off, looked and checked gears and primary gear, they seemed ok......bit worried by post, re little end knock.... will post some photos of my invesigation, also took carb off and stripped and cleaned them/it. ( twin carby thingy )

the xt is still making the noise, only on start up, was thinking now if its the plastic oil pump gear or there is a oil pipe banjo fitting at top of crank......i am just eliminating things as i go, the xt runs perfect at the moment.

denny.
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Old 21 Feb 2011
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Valves in spec?
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Old 21 Feb 2011
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Hi, sorry to put the wind up you. You won't necessarily know if its a woodruff key issue until you remove the nut and preferably the gear itself. Where in Cheshire are you? I might be able to provide some assistance.
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Old 21 Feb 2011
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Quote:
Originally Posted by bruken View Post
Hi, sorry to put the wind up you. You won't necessarily know if its a woodruff key issue until you remove the nut and preferably the gear itself. Where in Cheshire are you? I might be able to provide some assistance.
bruken, thanks for the reply, i did'nt take off the gear as i thought just checking visualy and moving the gear , there was no play in it, ruled it out, but can now see your point in removing the gear to visualy see the woodruff key.

i am commited to going to ireland ( hopefuly on xt ) this thurs/frid, i could at a push go next week, if you could spare some time and i would'nt be putting you out, i could travel up to you, to see what you think, ( have no garage or drive ) i have only put crankcase back on with gasket seal until i find and sort the problem.

re location i'm just on the wirral.

denny.
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Old 21 Feb 2011
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