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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.
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  #1  
Old 13 May 2004
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Gearbox parts

Hi, I have just bought a broken SRX600 which has the same engine as a XT600. The gearbox is broken.
I am stripping it down this week and have the motor pulled out and cylinder off and will split cases this week. I think 5th gear broke and damaged the gearbox.
I'm going to need some parts I guess. Can anyone here give me advice or what is likely to have broken and where I can buy the parts in the UK?
I also need a worshop manual to help me with putting it back together and setting timing etc. I found a parts list on the www but need a service manual as well.

Thank you

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  #2  
Old 13 May 2004
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just finished replacing my 5th gear on a xt600u
myself. not to hard, common problem apparently. consists of, two fifth gears $100aus each, main drive shaft gear needs to be pressed off and on $30,measure length of gear cluster and press back on to same lenth.clean all casings well and hope all those metal fragments from the gears didnt have a feild day with bearings and oil pump like they did with mine,i replaced every bearing and seal
for under $250 from a bearing wholesaler, make sure main bearings are stamped c3{hightemp},oil pump $300 ouch.if yours is passable make sure to clean or replace oil pickup $30.manual $100 another ouch.take time assembling bottom end double check and use locktight with all bolts and main bearings if a bit sloppy in casings, good quality selant
for the middle join,thats about it for now goodluck with the thumper

giggs
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  #3  
Old 20 May 2004
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Try this website: http://www.shayward.co.uk/srx600/

Excellent source of info on SRX6's.

There are differences between the SRX and XT so beware. 5th on my SRX6 went while I was on the motorway doing 70mph - it sounded awful but the only parts needed were two pairs of gears (4th & 5th) and two bearings.

Having said that I would very carefully check all parts for abnormal wear, as bits of metal flying about inside your engine may have done some damage.



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  #4  
Old 21 May 2004
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Thanks,
I now have it stripped and can only find one gear damaged the fifth 21T gear which is very lucky. That www site you recomended is great as it has a parts list to make it easier to order.
The failure occurred by the previous owner 2 years ago on the M25. Since then the bike was pushed into storage and finally sold to me via ebay for £200.
For some reason there was hardly any oil in the engine but it doen't seem to have damaged it. I can't work out where the oil has gone, the bike was covered in oily filth. I assume it has slowly leaked from the engine sprocket oil seal and covered the bike.
There must have been a lot of bits of metal flying around in the engine gearbox with half the teeth on that gear stripped off. I haven't found any bits. They must have been reduced to particles.
I'm re-checking all the bearings but they seem OK.
I think I will replace the gearwheel and get it back together so I can check the engine out on the road.
It's a nice looking bike but has been sadly neglected. Hope to have it back in fine condition in the next few weeks. Cosmeticaly it still looks good.
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  #5  
Old 21 May 2004
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Quote:
Originally posted by Anarchy:
[B]For some reason there was hardly any oil in the engine but it doen't seem to have damaged it. I can't work out where the oil has gone, the bike was covered in oily filth. I assume it has slowly leaked from the engine sprocket oil seal and covered the bike.B]
I'm assuming that you know the SRX/XT is a dry sump engine i.e. the oils is stored in an oil tank on the SRX & in the frame on the XT?

I mention this as you would not be first person not to know this. I'm not taking the p*ss BTW.

Regards

Steve

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  #6  
Old 22 May 2004
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I'd strongly recommend replacing all the bearings (and seals) while you're in there. They're cheap, redoing it in a month to replace one failed bearing (and the possible attendant damage to gears etc) isn't.

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  #7  
Old 22 May 2004
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Yes the oil tank was almost empty.
I now have found all the gearwheel debris inside the oil pump pick up. Nasty stuff. I gave the casing and bearings a good clean with Jizer then soapy water.

I agree that changing all the bearings would be worthwhile but where do you stop? Should the big end also be changed?
Really a full crank overhaul would be great at this stage.
To replace the bearings in the RHS case means pulling the crankshaft out with a special tool and having a new one fitted by a machine shop. I would incur outside labour costs that are quite high.
My worry is I haven't heard the bike run yet so don't know the real state of the bike.
I have really two choices.
1) Recondition the engine as new. All new bearings inc big end and new con rod. At the same time rebore, new piston etc.
2) Repair damage and reassemble, check rest of bike.

I have to keep things in perspective, its a £200 bike and already I have spent £150 on parts. It will need more spent to get it through an MOT such as tyres.
It's resale value is probably £600.

I have found Yamaha spares not cheap, about three times the price of Royal Enfield spares. My other bike is a Bullet.

I really do appreciate all of your help and advice, I'm not an expert and I'm currently unemployed so money is very tight.
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  #8  
Old 3 Jun 2004
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KEDO in germanny have a special 5th gear for XT all models, its said to be stronger than original.
I can't confirm it's true, though you could try it.

Matt
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  #9  
Old 3 Jun 2004
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I've got the bike back together and it runs fine, no smoke or nasty rattles.
Thanks to everyone that offered suggestions and advice. It's been interesting and fun bringing this bike back from the brink and the total cost including buying the bike has come to just under £350 which is a bargain.
They are an interesting rare bike, and I love the looks.

Cheers

Paul.
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