XT600 gearbox HELP!

[offrd]

Well bought myself an ole XT600 yesterday... Has got lots of reciepts for engine and gearbox bits etc.

Rode it home from rotorua today, got home, slipped it into neutral and leaned it on the sidestand and bugger me, the thing starts banging and clunking from in the gearbox and the chain jumps around!!!!:no:

Stuck it on the stand and leaned the bike over to lift the rear wheel off the ground, slipped it into gear and slowly let out the clutch, More bugger me! its locked up, wont turn the rear wheel much. Shut it down and stand it up... Bike wont roll! :confused:

Start it up and in neutral, it drives<_< then clunk and its slipped back in neutral!

So the story is two owners back it had 5th gears replaced, rings and valve guides, forks re-sealed and all sorts..

What im figuring is someone forgot to do something up tight and a gear is moving around:nono:

Lucky it never locked up on the highway and killed me and my daughter!!!!!:eek:

So who here can give advise on what is in there, what might be wrong and perhaps help out with a link to a manual or an actual manual?

Duncan

[tri boy]

First check for a loose shift lever/worn spline.
Could be worn, and not fully engaging/disengaging the gears.
Next, pop off clutch cover for a nosey.
Next, engine out. Strip n inspect. MHO

[dino3310]

shite there seems to be a bad run on second hand bikes with previous engine work going wrong lately...

glad you got home in one piece bro, could have been a nasty lockup

[JATZ]

What year XT ? got a couple of manual/handbooks here and a great big folder with a manual we got of the net

[offrd]

What year XT ? got a couple of manual/handbooks here and a great big folder with a manual we got of the net

Its a 1990.....

[offrd]

shite there seems to be a bad run on second hand bikes with previous engine work going wrong lately...

glad you got home in one piece bro, could have been a nasty lockup

Rather gutted, buying something that was done up, not the guys fault i bought it off, it was the previous owner that did or had the work done, he sold it as they never used it.....

Could have been a real mess!

[Motu]

As tri boy says - take it slow...work your way in from the outside.They are pretty simple inside,not much can be left out or not tightened - rear sprocket,crank and balance shaft which both have lock tabs.Clutch hub the same.Don't pull it out and strip down until you've had both covers off and had a good look.

[JATZ]

I'll have a flick through the manual's I got and see if theres any info in there that may be of help............ tomorrow :D

[dino3310]

was it that blue one on trade me which had $1200 worth of parts go into her, looked tidy...
good price:msn-wink:

[offrd]

I'll have a flick through the manual's I got and see if theres any info in there that may be of help............ tomorrow :D
Thanks!

Im thinking a lock tab on a nut/shaft allowing it to move to the left be the cause.... but where!

[offrd]

was it that blue one on trade me which had $1200 worth of parts go into her, looked tidy...
good price:msn-wink:

Yeah that's the exact one.....

[dino3310]

ohwell mate just think once shes fixed shell be good for another 50,ooo.... there pretty well known for turning over very high KLMs.... bike rentals love em

[offrd]

Well... Both engine side covers are off, cant see anything loose or floating....

Guess thats bad news for me......

[tri boy]

With the bike in neutral, check for extra shaft "float" (that be sideways movent), as well as for bearing failure of any sort.
If your got a bike mechanic bloke near by, ask him to pop in and see if he reckons crank case split, or if see's something simple. Could save you a grand.

[offrd]

With the bike in neutral, check for extra shaft "float" (that be sideways movent), as well as for bearing failure of any sort.
If your got a bike mechanic bloke near by, ask him to pop in and see if he reckons crank case split, or if see's something simple. Could save you a grand.

Cant feel any "float" anywhere. cant feel any bearing failure....

Dont know any bike mechanics.....:(

Sadly looking like a crank case split.......:weep:

Grand, Hmm that sort of sucks..... badly:pinch:

[alane]

My Clymer maual lists in "Transmission Troubleshooting"----incorrect shifting after assembly---check----

missing shaft shims
incorrect installed parts
shift forks bent during assembly
incorrectassembled shift linkageassembly
and other things that I dont think would apply.
another thing under "gears pop out of mesh"---is----insufficient shift lever spring tension.

There is a few circlips & washers in there ,so ,just one circlip not doing its job or a washer missing/in the wrong place ,would cause havoc.

I just did 3600 k,m,s going to & clompeting the Dustybutt, on my 87' 2kf(50k,s) with nothing more than a blown high beam filament as far as mechanical issues go.
It,s verry economic for a carbied 600. I got a tad off,ve 25km/ltr,going from picton to Hanmer & that included climbing up to 5500ft on Mt. Artimarlock.:niceone:
Did you check Twademe for manuals.?????
Good luck (sounds like ya need it) Alane

[offrd]

My Clymer maual lists in "Transmission Troubleshooting"----incorrect shifting after assembly---check----

missing shaft shims
incorrect installed parts
shift forks bent during assembly
incorrectassembled shift linkageassembly
and other things that I dont think would apply.
another thing under "gears pop out of mesh"---is----insufficient shift lever spring tension.

There is a few circlips & washers in there ,so ,just one circlip not doing its job or a washer missing/in the wrong place ,would cause havoc.

I just did 3600 k,m,s going to & clompeting the Dustybutt, on my 87' 2kf(50k,s) with nothing more than a blown high beam filament as far as mechanical issues go.
It,s verry economic for a carbied 600. I got a tad off,ve 25km/ltr,going from picton to Hanmer & that included climbing up to 5500ft on Mt. Artimarlock.:niceone:
Did you check Twademe for manuals.?????
Good luck (sounds like ya need it) Alane

Thanks for that!

I have found a manual on line and downloaded it now.... Looks like a factory one..

Now to find the time!

Sigh

[JATZ]

Sorry I didn't get back to you yesterday, but we had company, anyway....... Sounds like you got a manual sorted, prolly from the same place we got ours.
Have you tried this place>> http://www.cmsnl.com/yamaha-xt600ea-non-calcal-1990_model9647/partslist/
Lots of exploded diagrams of every part of your bike, They're bloody handyy to have on hand.

[offrd]

Well, it's my brothers bike now......

WIll post what we find when we get it to bits!

[thepom]

If you need an insight into stripping the engine look on youtube and type in yamaha srx engine disassembly and it shows a bloke stripping the yam 600 and it is basically the same as the xt ..... makes it look easy .bloody easy so I will be pulling mine apart soon for the 5 th gear whine and a rebore....bought my manual as a disc off a yank on e bay ....cheap too.....good luck with the strip and let us know what you find.....

[Armitage Shanks]

If you need an insight into stripping the engine look on youtube and type in yamaha srx engine disassembly and it shows a bloke stripping the yam 600 and it is basically the same as the xt ..... makes it look easy .bloody easy so I will be pulling mine apart soon for the 5 th gear whine and a rebore....bought my manual as a disc off a yank on e bay ....cheap too.....good luck with the strip and let us know what you find.....

Can't give any tech advice but...nice to know there's still a few fan's of the venerable Yamaha 600's around. I had an '86 XT600 in '89 which I travelled the country on followed by a couple of the TT600's which I used to ride and race , I actually won a race on my '89 Disc Brake model in '92, more good luck than good management I'm sure. I have a friend who has an '87 XT600 ( Blue) and he's just clicked over 170,000 kms, daily rider and regular oil and filter changes are the key. ( and Air filter of course ) . He still rides it every day. Awesome Bike and under-rated . My 5 Cents

[Padmei]

Sorry I didn't get back to you yesterday, but we had company, anyway....... Sounds like you got a manual sorted, prolly from the same place we got ours.
Have you tried this place>> http://www.cmsnl.com/yamaha-xt600ea-non-calcal-1990_model9647/partslist/
Lots of exploded Bits of every part of your bike, They're bloody handyy to have on hand.

fixed!
FTCR

[offrd]

Well the bike is all in bits:beer:

The problem has been located:beer:

A stinking $3.60 circlip on the shaft buggered.. allowing the gear to move JUST enough to catch the next gear...

Circlip and 2 cans of brake cleaner.. $25.00, Gasket set $158.00, Face of the mechanic that did not replace the clip.. BUGGERED if we get hold of him!

No damage done, one F*%$#*G circlip and full gasket set and a bro that knows much more about the insides of his bike later....:argh:

[dino3310]

fark thats alright bro, we found that the cause on mine was from the rebore(from a bike shop) was to tight for piston and she f@#ked the small end etc, bad servicing etc eventually chipped the hard face on some of the gearing.... 2k later and more to come:crazy: ... friggen sux but at least we know what we got now....

Glad you got i sorted mate.

[thepom]

Did you need any special tools or come across anything difficult or is it as straight forward as it looks.....

[offrd]

Did you need any special tools or come across anything difficult or is it as straight forward as it looks.....
My brother is doing the strip and rebuild. He has not said anything has been an issue so far!

[offrd]

Did you need any special tools or come across anything difficult or is it as straight forward as it looks.....
Had a look at the bike and a chat over the last few days, Pretty easy, you will need pullers and a air rattle gun to undo stuff makes it easier, or you will need two or more people to hold the motor down!
Its now riding around Rotorua mint as!

[alane]

YEAAA!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! Another 600 lives on-----------------------

[devi8]

luv these old pre80`s Yammys .... just spent 2k on me Tenere ... check me pics out, Retarded Motard

[TINA RAY]

Go get you money back and buy the bike on your avatar IMNSHO....:lol:

[TINA RAY]

oh....what size front wheel ?......

[Kickaha]

Go get you money back and buy the bike on your avatar IMNSHO....:lol:

You don't think that two years later he might be pushing it bit to ask for that?

[TINA RAY]

LOL...I tort it woz a recent post.....:crazy: