XT600 gearbox HELP!

**alane** · 25th January 2010, 22:17

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.

Did you check Twademe for manuals.?????
Good luck (sounds like ya need it) Alane

**offrd** · 26th January 2010, 05:14

Originally Posted by 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.

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** · 26th January 2010, 16:49

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-...647/partslist/
Lots of exploded diagrams of every part of your bike, They're bloody handyy to have on hand.

**offrd** · 6th February 2010, 21:30

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

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

**thepom** · 7th February 2010, 06:27

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** · 9th February 2010, 18:13

Originally Posted by 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.....

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** · 9th February 2010, 19:16

Originally Posted by 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-...647/partslist/
Lots of exploded Bits of every part of your bike, They're bloody handyy to have on hand.

fixed!
FTCR

**offrd** · 20th February 2010, 13:04

Well the bike is all in bits

The problem has been located

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....

**dino3310** · 20th February 2010, 16:37

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

... friggen sux but at least we know what we got now....

Glad you got i sorted mate.

**thepom** · 21st February 2010, 08:46

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

**offrd** · 21st February 2010, 09:01

Originally Posted by thepom

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** · 26th February 2010, 13:42

Originally Posted by thepom

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!