XT600 gearbox HELP!

**offrd** · 24th January 2010, 18:45

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!!!!

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!

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

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

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** · 24th January 2010, 19:51

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** · 24th January 2010, 19:58

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** · 24th January 2010, 20:00

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

**offrd** · 24th January 2010, 20:06

Originally Posted by JATZ

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** · 24th January 2010, 20:08

Originally Posted by 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

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** · 24th January 2010, 20:18

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** · 24th January 2010, 20:22

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

**dino3310** · 24th January 2010, 20:26

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

**offrd** · 24th January 2010, 20:26

Originally Posted by 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

Thanks!

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

**offrd** · 24th January 2010, 20:35

Originally Posted by dino3310

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

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

**dino3310** · 24th January 2010, 20:40

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** · 25th January 2010, 17:48

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

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

**tri boy** · 25th January 2010, 18:23

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** · 25th January 2010, 18:45

Originally Posted by 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.

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

Dont know any bike mechanics.....

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

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