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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.
Photo by Ellen Delis, Lagunas Ojos del Campo, Antofalla, Catamarca

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Photo by Ellen Delis,
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  #1  
Old 3 Jun 2011
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crankcases
Just rebuilt my crankcases and I can,t get the gears to work so its all coming apart again....gears seem stuck.....
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  #2  
Old 4 Jun 2011
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Keny,

Is there any end float on the output shaft? There should be just a little when you push or pull on the end where the countershaft sprocket normally would sit.

Pawlie
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  #3  
Old 5 Jun 2011
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mmmn....don,t think there is.There is a large spacer on the the end of the output shaft and I,m wondering if it is the right thickness?
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Old 5 Jun 2011
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Keny,

If zero end float... you are gonna need to take it apart and see what is up. Once assembled you should be able to turn the countershaft by hand and click/shift the gearbox up and down through the gears. If this is not possiable then something is wrong.

What is wrong is a bit byond my scope. I am just a " backyard " wrench turner who has repaired my own xt6 gearbox. Not an expert.

I do recall a stock shim being present against the case upon gearbox disassembly. I don't recall if it was input or output shaft that had the shim. I have been told that this shim is present or not, based on need at the time of factory assembly.

Have you pressed new gears on the shaft? Disassembled and reinstalled gears on shaft the right way around? This proceedure needs to be performed correctly for everything to align up upon case reassembly.

All the best,

Pawlie
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  #5  
Old 6 Jun 2011
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There is something wrong somewhere,when I install the old gearbox I can turn everything and engages well but on installation of the electric start gearbox with the longer spacer it won,t work,maybe I need a slightly smaller spacer,I ll look in my box of bits and see if anything looks as though it might help. I,m in the same boat as you,just a home mech but thanks for the time and advice,its always welcome........
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Old 6 Jun 2011
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Hey pawlie,just checked the parts manual for both bikes and I see a slight difference in shape and part numbers between the gear selector forks and maybe the drum so I will pull it apart tomorrow and recheck the forks-possible I mixed up the selector forks-will keep you informed.....
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Old 6 Jun 2011
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Keny,

I'm not familiar with the two different bikes/engines you are refering to.....

My bike is the OLD style kick only w. countershaft sprocket held in place with two small M6 or M8 bolts.

It is my understanding that early and later xt gearboxes , (with electric start and countershaft held in place with large nut) are not compatible for parts interchange.

Hopefully you are not trying to combine the above two types of gearbox.

I am not 100% sure about the above statement but seem to remember someone saying the output shaft is slightly longer on the later bikes. and therefore not suitable for a swap.

Perhaps someone with more experience could confirm or deny the above.

Good luck,

Pawlie
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Old 6 Jun 2011
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Now I,m worried...............I have an original 86 engine kick and electric start and an old 85 kickstart only. My cases were broken on the electric start so I got new cases from germany and am now rebuilding the old electric start one.I think I may have mixed up the selctor forks and drum so will re inspect what I have done.

The electric start one has the gearbox output shaft 20mm longer than the kickstart shaft due to the electric casings being wider for the starter motor housing. There is a spacer 20 mm thick which goes on the end of the shaft for the electric one so I ,m ..................just had a flash......when I put the old kickstart gears in it worked fine but when I put the electric start gears in it would not work so now I,m thinking the forks and drum are wrong. I think I,m using the kickstart forks and drum on the electric box hence the problem.......

Hope its a bit clearer and I ll let you know tomorrow...
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Old 7 Jun 2011
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Right, pulled the selector forks and drum and replaced with the other ones and now works ok,re assembled and found still no end play on output shaft and can,t turn by hand. Does it only turn with the clutch attached or should I be able to turn the output shaft by hand ?
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Old 7 Jun 2011
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Should be able to turn by hand and click through the gears while turning. Zero endfloat is no good.

Something is still not right.

Pawlie
Last edited by Pawlie; 7 Jun 2011 at 07:14. Reason: clarity
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  #11  
Old 7 Jun 2011
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Oh crap......strip down again tomorrow then....
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