Go Back   Horizons Unlimited - The HUBB > Technical, Bike forums > Yamaha Tech
XT600e Gear Lever XT600e 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 26 Dec 2006
Registered Users
HUBB regular
  
Join Date: Nov 2002
Location: Cornwall,UK
Posts: 63
Question XT600e Gear Lever
I've not found the XT gear lever to be a particularly reliable part - unlike the rest of the bike: Within hours of tightening the pinch bolt it's loose on the splines of the gear shaft and eventually I'm sure that the splines will get damaged. The problem seems to be the design (I'm on my 3rd) and although they do get severely abused (hitting ruts/rocks offroad), my Montesa does the same stuff and has a perfectly tight lever.

Question are the TT / TTR levers any better designed/constructed and will they fit or has anyone modded or used anything else?

Thanks Bish
Reply With Quote
  #2  
Old 26 Dec 2006
Registered Users
New on the HUBB
  
Join Date: Dec 2006
Location: new york state
Posts: 10
XT Gear Lever?
I have a XT600 84 model, and have a gear lever off a TT600 84 model. Works good. Found on E-bay. I just put a longer bolt in and double nut the the bolt. Hope this helps. Hi, To everybody, first post to The HUBB!
BIG ED XT&TT 600 FAN!!
Reply With Quote
  #3  
Old 27 Dec 2006
Brian Williams's Avatar
Contributing Member
Veteran HUBBer
  
Join Date: Oct 2006
Location: england
Posts: 137
Just use a longer bolt and a nylock nut or two.
__________________
rust & dust
Reply With Quote
  #4  
Old 27 Dec 2006
Registered Users
HUBB regular
  
Join Date: Nov 2002
Location: Cornwall,UK
Posts: 63
Unhappy XT600e Gear Lever
Hi - Thanks for the advice... I actually do the longer bolt with the nut on the end trick and loctite it all up - the bolt's never loose. The issue seems to be the rather spindly spline part of the gear lever (and perhaps that it's steel? the alloy ones get pinched harder by the bolt). If there was room I'd tap the threads up a size and be able to torque it harder with a bigger nut & bolt...

I'll have to suss out some other Yam offroad models and see if I can get a more robust lever off another model that will fit.
Reply With Quote
  #5  
Old 27 Dec 2006
Registered Users
HUBB regular
  
Join Date: Mar 2006
Location: N.Ireland
Posts: 54
Wink
try getting a hacksaw and sawing through the slot in the gear lever to widen it a bit. If, whenever you tighten the bolt up, the slot is completely closed, the gear lever might not be clamping fully on the shaft. \Squeeze the slot closed in a vice and saw through, then when you loosen the vice, the slot should be a fair bit wider and will clamp securely on the shaft This worked for me as mine always seemed slack.
Reply With Quote
  #6  
Old 28 Dec 2006
Registered Users
Veteran HUBBer
  
Join Date: Aug 2001
Location: sunny England
Posts: 790
sounds like the gear lever has vibrated and worn a bit on the splines, hopefully the lever is softer than the shaft and thats not worn! you could try the old windscreen wiper trick of sandwiching a bit of tinfoil in there?
__________________
dave
Reply With Quote
  #7  
Old 1 Jan 2007
Registered Users
HUBB regular
  
Join Date: Nov 2002
Location: Cornwall,UK
Posts: 63
Thumbs up XT600e
Thanks - I'll try widening the slot trick to get the clamp pinched up more, as despite only put it back on a few days ago, a days trail riding has clobbered it.
Reply With Quote
  #8  
Old 20 Jan 2007
Registered Users
HUBB regular
  
Join Date: Nov 2002
Location: Cornwall,UK
Posts: 63
Thumbs up XT600E Gear Lever Fix
Thanks gavxt600e - the widening of the pinch by hacksawing worked a treat. After refitting and torquing it up about 3 times (after it bashing a rock or 2 trail riding!) and the lever is at last on the splines like a limpet... now only if Yamaha had thought of that!
Reply With Quote
  #9  
Old 16 Apr 2010
Registered Users
HUBB regular
  
Join Date: Mar 2008
Location: Adelaide, South Australia
Posts: 22
Gear Shift Grub Screw Fix
Try this instead of stretching and stripping threads, hack sawing out gaps, rock bashing and sewing needle insertion! Weld on an M10 or 3/8" nut on the boss, the lever boss is also tapped to match whatever toothed grub screw you can get! Never slips! Drill or file a little seat for the grub screw teeth in the shaft as well. Another Aussie made and tested design.

Cheers.
Attached Thumbnails
XT600e Gear Lever-loose-srew-lined-up.jpg  

Reply With Quote
  #10  
Old 31 Oct 2010
Registered Users
HUBB regular
  
Join Date: Mar 2010
Location: Canberra, Australia
Posts: 23
I am suffering the same problem. I have a bad vibe the grooves on the spline are worn as I have tried three gear levers (my original bush-bashed one, a steel XT600 one and an alloy XT600 one) and they are all loose, the last two considerably loose. I hacksawed the old bush bashed one and still no go.

I don't quite understand the grub-screw arrangement in the last post, so if anyone could shed some light it would be appreciated.

I am thinking I might have to get a sleeve heated and put over the spline and then re-grooved. Any ideas?
Last edited by Double Supercool; 1 Nov 2010 at 10:49. Reason: My grammar sucks
Reply With Quote
  #11  
Old 1 Nov 2010
bacardi23's Avatar
Registered Users
Veteran HUBBer
  
Join Date: Sep 2007
Location: XXX<-Portugal->Azores->Santa Maria (island)
Posts: 1,544
I got this!



[url=http://www.motoclasse.com/index.php?mod=catalog&action=viewProduct&product_i d=1769]Motoclasse | Acess
Last edited by bacardi23; 1 Nov 2010 at 13:03.
Reply With Quote
  #12  
Old 1 Nov 2010
Registered Users
HUBB regular
  
Join Date: Mar 2010
Location: Canberra, Australia
Posts: 23
I will check it out. If nothing else, I will have a large collection of levers!
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
Help! Seeking Gear! First Time - Seeking Support Travellers' questions that don't fit anywhere else 0 10 Oct 2006 09:03
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 12:33.

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