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.
Contact Overland Solutions for all your custom modifications and setup for overland travel.

Reply
 
LinkBack Thread Tools Display Modes
  #1  
Old 7 Aug 2013
Registered Users
Veteran HUBBer
 
Join Date: Nov 2009
Location: christchurch newzealand
Posts: 384
dead again

riding home last night....took off from the trafic lights and gearbox jumped out of gear to a rerrible sound of crunching .....every time gave it the throttle it jumped out of gear to awful sounds.....up at five to check chain and sprockets hoping it was something simple....no luck.....looks and sounded internal so back to square one and engine out and dtrip and inspect....gutted....will report back....
Reply With Quote
  #2  
Old 7 Aug 2013
Registered Users
Veteran HUBBer
 
Join Date: Sep 2012
Location: Middle USA
Posts: 256
Sorry to hear that. Krunching is never good....
Reply With Quote
  #3  
Old 7 Aug 2013
*Touring Ted*'s Avatar
Contributing Member
Veteran HUBBer
 
Join Date: Jul 2005
Location: Wirral, England.
Posts: 4,425
Before you start going crazy assuming the gearbox is toast and tearing your engine apart, check out the selector mechanism first...

And is your clutch working okay too ???
__________________
www.TouringTed.com
1994 XR650L
2001 NX650 Dominator.

BMW Dealer Technician
Welder/Fabricator

Ushuaia - Colombia 2007/8
UK- South Africa 2010/11
India 2012
Yukon 2012
S.E Asia 2014
U.K - Magadan 2015
Reply With Quote
  #4  
Old 8 Aug 2013
Registered Users
Veteran HUBBer
 
Join Date: Nov 2009
Location: christchurch newzealand
Posts: 384
yeah clutch working but I ll start with that and if its ok I pull the engine and do the gearbox...no warnings or noises just sudden....just been out to check the clutch and I can put it in gear but when I pull the cable its not disengaging....maybe a clutch problem ?

Last edited by kenymact; 8 Aug 2013 at 08:51. Reason: checked the clutch
Reply With Quote
  #5  
Old 10 Aug 2013
kentfallen's Avatar
Registered Users
Veteran HUBBer
 
Join Date: Jan 2008
Location: Isle of Sheppey, Kent, England, UK
Posts: 668
Quote:
Originally Posted by kenymact View Post
maybe a clutch problem ?
Thank goodness for that!

Could have been terminal.
__________________
Triumph Bonneville 800 (2004), Yamaha XT600E (1999), Honda XBR500 (1986).

Reply With Quote
  #6  
Old 11 Sep 2013
Registered Users
Veteran HUBBer
 
Join Date: Nov 2009
Location: christchurch newzealand
Posts: 384
Update....not good...removed engine and stripped gearbox to find the selector fork for second gear worn....worn one side flat so checked the second gear which is at the end of the gearbox shaft closest to the crankcase casing...

On inspection noticed the gear might have been put in 180 degrees out....when put in the other way it fouls against the casing?...gearbox is assembled per the manual with the spacer in place ,cant see if there should be a shim there but the manual does say "make sure all shims are in place ".......

the selector fork was ground away because the gear was holding it the wrong place and that's why it rode for 1000kms before it stopped doing its job.....when I assemble the gears the way it came aprt it works fine but when the gear is put 180 it grinds and becomes notchy....

Any inupt welcome as I cant reassemble till I find the problem....I ll check the bearing is fully seated....

I ll check again tonight and see if my mates can source the problem....
Reply With Quote
  #7  
Old 13 Sep 2013
Registered Users
Veteran HUBBer
 
Join Date: Nov 2009
Location: christchurch newzealand
Posts: 384
Initially thought I may have put the gear in 180 degrees out but wont fit if you put it in wrong....fork does not appear to be bent so cant figure out why it has ground half of the selector fork lower leg away.....don't know if its possible to bend one if your hard on selecting a gear.....anyhoo....have replaced fork selector and will have the gears undercut by a local engineering firm just to make sure then rebuild the engine and hope it doesn't happen again....pissed off I have not been able to identify the issue......
Reply With Quote
  #8  
Old 14 Sep 2013
Registered Users
Veteran HUBBer
 
Join Date: May 2013
Location: Wisconsin, USA
Posts: 313
Can you post some pics of what is happening? To grind the fork away something has to be either pushing on it at all times which they shouldn't. The forks should be sitting with some gaps on each sit, just hitting when actually changing gears, then back to being free from hard contact. It is possible to bend a fork and then it will always be pushing on a gear when it shouldn't. Compare the new fork to the old and see if there is a difference. Does the drum have any wear marks or any of the guide shafts ect. straight.

Shifting without using the clutch can bend forks same with excessive force when jamming through gear changes.
Reply With Quote
  #9  
Old 14 Sep 2013
*Touring Ted*'s Avatar
Contributing Member
Veteran HUBBer
 
Join Date: Jul 2005
Location: Wirral, England.
Posts: 4,425
It could be that you are over shifting. There should be a limiter mechanism. Maybe this is not working or installed incorrectly.
__________________
www.TouringTed.com
1994 XR650L
2001 NX650 Dominator.

BMW Dealer Technician
Welder/Fabricator

Ushuaia - Colombia 2007/8
UK- South Africa 2010/11
India 2012
Yukon 2012
S.E Asia 2014
U.K - Magadan 2015
Reply With Quote
  #10  
Old 14 Sep 2013
Moderated Users
Veteran HUBBer
 
Join Date: Apr 2008
Posts: 502
I reckon you've missed out a shim, mate, or put one in the wrong place.
Reply With Quote
  #11  
Old 14 Sep 2013
Registered Users
Veteran HUBBer
 
Join Date: Nov 2009
Location: christchurch newzealand
Posts: 384
The fork was well ground away.....cant understand why and there are no shims according to the parts book or rebuild manual.....I ll put the cases back together and check the operation again....I ll take a photo and see if I can put it up...
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
Calling All Friendlies - Vancouver - Dead Horse/Prudhoe Bay AC North America 5 19 Jul 2013 00:42
dead bike oddity anotherrick Yamaha Tech 14 4 Mar 2013 19:07
The return of the dead bike bkm_br The HUBB PUB 2 1 Mar 2012 14:27
National Luna Battery Monitor Dead GavinF 4WD Overland Tech 5 25 Jan 2012 19:22

 
 


HU DVD Summer Special!

Now that summer is here, get On the Road! Take 30% off the Achievable Dream - On the Road! 2-DVD set until August 31 only. Get On the Road! Learn the tips to staying healthy, happy and secure on your motorcycle adventure!

Our veteran travellers share their tips (and great stories) for staying healthy, happy and secure on your motorcycle adventure.

"A fantastic, informative and inspirational DVD."

"It's brilliant - thank you very much!"

Check it out at the HU Store! Remember to use Coupon Code 'ONTHEROAD' on your order when you checkout.


Renedian Adventures


Renedian Adventures

What others say about HU...

"I just wanted to say thanks for doing this and sharing so much with the rest of us." Dave, USA

"Your website is a mecca of valuable information and the DVD series is informative, entertaining, and inspiring! The new look of the website is very impressive, updated and catchy. Thank you so very much!" Jennifer, Canada

"...Great site. Keep up the good work." Murray and Carmen, Australia

"We just finished a 7 month 22,000+ mile scouting trip from Alaska to the bottom of Chile and I can't tell you how many times we referred to your site for help. From how to adjust your valves, to where to stay in the back country of Peru. Horizons Unlimited was a key player in our success. Motorcycle enthusiasts from around the world are in debt to your services." Alaska Riders

contest pic

10th Annual HU Travellers Photo Contest is on now! This is an opportunity for YOU to show us your best photos and win prizes!

NEW! HU 2014 Adventure Travel T-shirts! are now available in several colors! Be the first kid on your block to have them! New lower prices on synths!

HU 2014 T-shirts now in!

Check out the new Gildan Performance cotton-feel t-shirt - 100% poly, feels like soft cotton!


What turns you on to motorcycle travel?


Global Rescue, WORLDwide evacuation services for EVERYONE

Global Rescue is the premier provider of medical, security and evacuation services worldwide and is the only company that will come to you, wherever you are, and evacuate you to your home hospital of choice. Additionally, Global Rescue places no restrictions on country of citizenship - all nationalities are eligible to sign-up!


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 R80 G/S motorcycle.

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 (22 this year!); 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, the HUBB or to receive the e-zine. 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.


Books & DVDs

amazon

All the best travel books and videos listed and often reviewed on HU's famous Books page. Check it out and get great travel books from all over the world.


Motorcycle Express for shipping and insurance!

Motorcycle Express

MC Air Shipping, (uncrated) USA / Canada / Europe and other areas. Be sure to say "Horizons Unlimited" to get your $25 discount on Shipping!
Insurance - see: For foreigners traveling in US and Canada and for Americans and Canadians traveling in other countries, then mail it to MC Express and get your HU $15 discount!




All times are GMT +1. The time now is 01:56.