Go Back   Horizons Unlimited - The HUBB > Technical, Bike forums > Yamaha Tech
Yamaha Tech Originally the Yamaha XT600 Tech Forum, due to demand it now includes all Yamaha's technical / mechanical / repair / preparation questions.
Photo by Daniel Rintz, Himba children, Namibia

The only impossible journey
is the one
you never begin

Photo by Daniel Rintz,
Himba children, Namibia



Reply
 
LinkBack Thread Tools Display Modes
  #1  
Old 20 Nov 2007
Registered Users
HUBB regular
 
Join Date: Feb 2007
Location: Poland
Posts: 20
Damping rod holder

Hi
Does anyone know what special tool is needed to disassemble front fork of 1991 XT 600 (3TB). The problem is a damper rod turning while trying to loosen the bottom bolt. I heard there is Yamaha special tool (but do not know the number). I’d like to make it myself but have no idea what it looks like. Does anyone have a picture of the tool?
************************************************** *********
Maybe someone had similar problem with a gearbox: It’s very, very difficult to shift to neutral when the bike is not moving and the engine is running. It’s getting impossible when the engine is hot. I have to shift to neutral at 20-30 kph. Then again, when the engine is stopped (even if very hot) – no problem at all with changing to neutral. What‘s the reason for this?

Thanks,
Michal
Reply With Quote
  #2  
Old 20 Nov 2007
Registered Users
Veteran HUBBer
 
Join Date: Aug 2007
Location: Sax, Spain
Posts: 901
odd shifting

dont know if this is related but...... my 1989 XT600 was difficult to pull clutch in when engine was hot, it was good when cold, and cable was new one I had just purchased.
turned out that the routing was wrong and the cable was touching the cylinder and getting hot and then stiffening up when it expanded making gearchanges difficult.


Martyn
Reply With Quote
  #3  
Old 20 Nov 2007
Registered Users
Veteran HUBBer
 
Join Date: Apr 2006
Location: Staffordshire. uk
Posts: 766
The easiest way to get the bolt out of the bottom of the fork without holding the damper rod is to use an air ratchet. Like the ones the tyre guy's use to get wheel nuts off. The hammering will soon have it undone. I've tightened it up the same way but getting the right torque is a bit hit and miss. If it's not tight enough oil will leak out !
Reply With Quote
  #4  
Old 21 Nov 2007
Nigel Marx's Avatar
Super Moderator
Veteran HUBBer
 
Join Date: Oct 2000
Location: South Island, New Zealand
Posts: 798
Thumbs up Clutching at broom handles!

Sounds a lot like the clutch is dragging. As suggested, check the cable routing, check to see that the cable outer has not been crushed so that it is gripping the inner, and check adjustment (should be a few mm free movement of inner cable at the lever). If these are OK, then it may be a warped (slightly bent) metal plate, or the fingers of the clutch basket have grooves in them, thus not allowing the plates to properly separate. Do you have any idea how many kms old the clutch is?

I don't know about the XT600 but on other Yamahas I have held the damper rod on the inside with the end of a wooden broom handle. It needs to be a thin broom handle, and you have to hammer it in a bit for it to bite into the socket in the head of the damper rod. It's an easy thing to try. Also Flyingdoctor is right, an air wrench usually does it, but I have had to use the broom handle AND air wrench on several occasions.

Regards

Nigel in NZ
__________________
The mouth of a perfectly contented man is filled with . -- 2200 BC Egyptian inscription
Reply With Quote
  #5  
Old 21 Nov 2007
Registered Users
Veteran HUBBer
 
Join Date: Feb 2007
Posts: 289
Quote:
Originally Posted by michal4 View Post
what special tool is needed to disassemble front fork of 1991 XT 600 (3TB)
it's a 27 mm nut (external size), so you need to buy about 60 long screw for that size of nut, weld a nut at one end and a T handle on the other
Reply With Quote
  #6  
Old 21 Nov 2007
Contributing Member
Veteran HUBBer
 
Join Date: Oct 2002
Location: montana usa
Posts: 547
XT600 forks

Just did the forks on a 90 XT600 (one of the few inported to the USA). As I have done on lot's of forks I stuck my 10 mm 3/8 drive allen in the fork bottom, I made a long one from a straight peice of 10mm allen stuck in a 10mm socket. Then I laid the fork leg on the floor and plugged my trusty 3/8 ratched in and whacked it with a hammer. This usally breaks the bolt loose to where I can twist it to start to loosen the bolt. Now the damper rod is turning so I plug my 3/8 air wrench on and put the spring back in the fork and while pushing down on the fork spring I zip the bolt out with the small air wrench. When putting the bolt back in I like to use some silicone seal on the bolt threads that is very vibration proof and prevents leaks.
Reply With Quote
  #7  
Old 21 Nov 2007
Registered Users
Veteran HUBBer
 
Join Date: Nov 2004
Location: USA
Posts: 992
Use a stick of wood down in there to apply pressure.
Reply With Quote
  #8  
Old 21 Nov 2007
Registered Users
HUBB regular
 
Join Date: Feb 2007
Location: Poland
Posts: 20
Thanks All,
Regarding damping rod
I will test all the methods you describe: air wrench, broom handle. It is interesting how strong the allen bolt keeps the damping rod. I used a lift to compress all the length of the spring (even a bit more) but still was unable to stop the damper rod. Then tried to make a tool to stop it. Took 27 mm nut, put on an end of wooden stick and put that into the tube. It fitted perfectly but I couldn’t hold the damper – the stick with the nut rotated almost freely inside. It looked there is no interaction between bottom allen bolt and 27mm nut on the stick. Then I rejected the 27mm hypotheses.

Regarding gear box neutral
The bike is 16 years old, 4 years with me, I did 40K km. There was always a problem to shift to neutral with running engine. 3 years ago I opened the engine, did some research. The 5-th gear was worn – so replaced with new one. It had also B size piston. I guessed the bike was 80K km then. Clutch basket fingers had small groves 1-.5 mm (20-40 mils). I blended it. The gear box looked OK, no problem with changing the gears. After this improvement (and assembling of course) it was the same: when engine was stopped – no problem, when running – problem, when hot – not possible to shift to neutral at all. 3 years later it got even worse. Can it be the clutch?
Thanks again
Michal
Reply With Quote
  #9  
Old 22 Nov 2007
Registered Users
Veteran HUBBer
 
Join Date: Nov 2004
Location: USA
Posts: 992
You want to mash a stick (board, or something that will semi conform to the grooves) against the top of the rod (but is wider than the rod) as you turn the bolt.

If that won't work, take an air gun and a few cuss words to it...
Reply With Quote
  #10  
Old 24 Nov 2007
Registered Users
Veteran HUBBer
 
Join Date: Nov 2002
Location: Surrey, UK
Posts: 183
Quote:
Originally Posted by cyberzar View Post
it's a 27 mm nut (external size), so you need to buy about 60 long screw for that size of nut, weld a nut at one end and a T handle on the other
Hi,

The Yamaha part#s appear to be 90890-01326 (T-Handle) & 90890-01388 (Damper Rod Holder 27mm). There is a reference to it in the 3TB Service Manual and the very small drawing looks very much as described, although with it being purpose made there is no need to weld the two together.

Ciao,
Geoff

Footnote - hows your Italian (although the pictures say a thousand words)? 'LINK'

Last edited by GeoffE; 24 Nov 2007 at 15:08.
Reply With Quote
  #11  
Old 25 Nov 2007
Registered Users
Veteran HUBBer
 
Join Date: Feb 2007
Posts: 289
special tool

ok here some pics taken from a tutorial made from a friend.. ciglio from xt600 italia

two nuts foer each end, threaded bar size 18 (27 nut), rubber along to avoid scratches on internal of stanchions.

Last edited by cyberzar; 29 Jan 2008 at 21:49.
Reply With Quote
  #12  
Old 25 Nov 2007
Registered Users
Veteran HUBBer
 
Join Date: Feb 2007
Posts: 289
final pic

and here is the completed hyper tech tool!

Last edited by cyberzar; 29 Jan 2008 at 21:49.
Reply With Quote
  #13  
Old 26 Nov 2007
XTfubar's Avatar
Registered Users
HUBB regular
 
Join Date: Oct 2006
Location: Canada
Posts: 33
Well..blow my seals !

Hi..the only thing I've done with forks is to change the seals. I overfilled the fork with oil, sealed it back up and then compressed the fork with a hydraulic jack to push put the fork seal( after removing the circlip).Otherwise I've heard an impact wrench is usually required.
Reply With Quote
  #14  
Old 10 Jan 2008
Registered Users
HUBB regular
 
Join Date: Feb 2007
Location: Derbyshire
Posts: 17
With regard to a tool to undo yer forks
I got a 12mm setcrew 50mm long on to that I screwed 2 nuts ( 12mm )
onto the end of that I welded a 5/8 whit nut That nut slips over the remaining thread
Then I put a 19mm socket on the setscrew end ( with the help of the extra nuts it stops straight ) on that I put 2 -300mm ( 1 foot ) socket extensions
then ratched it undone
I had to do it this way as the capheads at the bottom of the forks were all gunged and rusted into their reccesses
After undoing the forks I roasted the fork ends with a blowlamp and easing oil did the rest. When I replaced the setscews I wraped them in PTFE tape to stop ingress of dirt and water

HTHY Mick
__________________
Cant leave a trail for others to follow by sitting on yer arse
Reply With Quote
Reply


Currently Active Users Viewing This Thread: 1 (0 Registered Users and/or Members and 1 guests)
 
Thread Tools
Display Modes

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
Large float rod for 41 litre Tourtech petrol tank bimota Other Bikes Tech 4 11 Nov 2007 12:19
Wanted: Roadbook holder (in UK) chris TRAVEL Equipment for Sale / Wanted 0 17 May 2007 23:00
Touratech Road Book Holder for sale Giles4060 TRAVEL Equipment for Sale / Wanted 2 19 Oct 2006 13:10
XT600E fork damper holder tool? Photo Yamaha Tech 2 3 Jun 2004 00:07
Garmin 38/40/12XL holder for sale Chris Scott Navigation - Maps, Compass, GPS 0 8 Mar 2003 16:29

 
 

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

HU Event and other updates on the HUBB Forum "Traveller's Advisories" thread.
ALL Dates subject to change.

2024:

Add yourself to the Updates List for each event!

Questions about an event? Ask here

HUBBUK: info

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...

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!

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 12:39.