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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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Old 2 Feb 2005
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Location: stgo, chile
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starter gear damaged

Hi mates, i was begining my trip to south of my country and suddenly there was a knocking sound coming out of the engine very loud and i just thought that i would check it later.

Then 400 kilometers and the xt couldn't start again,there was a knocking sound very loud while i was cranking the engine and then then the starter started to sound softly and that was it.

The mechanic told me there was a problem with the starter gear and 3 bolts with his head cutted where there are 6 bolts attached to the magneto wheel and figured it out where are that little pieces in all the motor i think.

Is this a known problem with these engines or is it bad luck? any comments please

That was my journey in 2 days,1000 kilometers in 1 and a half day

bad luck but who knows

my bike is an 98 xt 600 e 3TB

[This message has been edited by xt performer (edited 02 February 2005).]
Regards, Victor
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Old 2 Feb 2005
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Location: Toulouse, France
Posts: 231
Not a common problem on XT´s for sure.
I see three possibilities:

1(most probal to me): fabrication/remounting failure, those bolts should be tightened with lochtite; much torque from starter.
2 long use of a weak battery could eventually damage the gear as well known on triumph 900 triples.
3 crank bearing worn out and some problem with cam chain.

What is the km stand of the bike?
Did you experience electrical problems before the brake down, even small ones?


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Old 2 Feb 2005
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hi matt,it has only 45000 kms and the cam chain was changed at 39000 kms,maybe when the mechanic tightened these bolts didn't used loctite and the correct torque neither,the battery is full ok but when he changed the cam chain it could be a problem,thanks mate
Regards, Victor
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Old 9 Mar 2005
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hi mates,finally i removed the left engine cover and there's only 3 bolts attached to the magneto,and these bolts were cutted, why?...i have no idea,but then i think these bolts are from a very high grade that made them too hard so i replace them with other bolts with a lower grade,much softer and for that reason these bolts can stand the vibrations i guess.

the question is.....

in the 6 holes on the magneto there are 3holes for a tool that remove the magneto where these holes have thread in the starter clutch only and the others 3 holes have thread in the starter clutch and the magneto.

i fitted these bolts in the starter clutch holes only and for this reason i think it would be better for the crank vibrations for the bolt but if the bolt got cut,the bolts head would go directly to the engine and transmission,i know that but i think these holes (thread in the starter clutch only and no the others holes with thread in the starter clutch and magneto)would be good for the bolt to not get cut.

sorry for my english and please any idea or comment would be welcome.
Regards, Victor
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