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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 28 Oct 2007
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striped gear lever

Hi the gear change lever and shaft on my XT 3AJ has completly worn the splines away.
I have managed to get it on tight but it wont last long (untill I fall off )
I think the engine has to be split to change the shaft but have been told by 2 mechanics that it is possible to remove most Yamaha gear change shafts from the clutch side.
Has any one done this or know if its possible?
Thanks
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  #2  
Old 28 Oct 2007
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If I understand this correctly then I can feel a Cambodian field repair coming on.


If you want a quick repair that you can take off later then fit the lever on the shaft and get a local guy to drill a hole right the way through it, as you should already have a hole in the lever just use that as a guide, then get a bolt or a piece of wire and make a split pin for it (just like your footpegs are connected to the bike).

If the lever is ok and the gear box is ok, then weld the damn thing on if all else fails, it will get you whatever major city you need to get to make a decent repair.

If I've misunderstood the question, then If you can get a picture of it to me that would be very helpful.
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  #3  
Old 28 Oct 2007
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I think I need to make it a little more clear after reading this again...

Imagine the Earth then imagine the North South Pole line that goes through it, that's what you need to do with the bolt, it shouldn't move then.
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  #4  
Old 7 Nov 2007
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yep i agree.....

Im with Judadredd on this one........ a small bolt drilled down through rhe middle was exactly what I had to do on a CG125 many many moons ago when i was but a skint young lad and on the dole..... them were the days WHEN YOU COULD GET A WORKING BIKE FOR A FIVER!
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  #5  
Old 7 Nov 2007
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Martyn,

Welcome to the Home of Cambodian Field Fixers, we don't need no stinking workshops the side of the road, some wire and tape and we are happy.

Oh the joys of owning your own motorcycle
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  #6  
Old 7 Nov 2007
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cambodian field fix my wiring loom...........please?

my wiring loom is banjaxed, knackered, demised, dead, proper poorly like.......

to the point of making my lights and any other electrical stuff not work intermittently, i dont care about the horn, i can shout, or the indicators i can wave an arm about... but at night it helps if the lights stay on when you live in the countryside and there are large ditches and cactuses or cactii ( both are correct) in abundance to run into...... I have rebuilt this bike from the ground up, just ordered another 160 euros worth of carburettor parts and a new fuel tap for her, but the wiring is driving me MAD!
all i want is a new loom and i will be happy. part number 2KF-82590-00 now discontinued.

any ideas?
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  #7  
Old 7 Nov 2007
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Wiring loom

You're going to make one then, from scratch?
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  #8  
Old 7 Nov 2007
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may have to.........

not looking forward to it I can tell you.
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  #9  
Old 8 Nov 2007
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universal wire harness

Hi.

If you donĀ“t care about your indicators and horn etc... and only want your lights to work why not just buy one of those universal set ups that you can buy for puting a set of extra lights on your car? they come with relays and connectors. then you just cut the cables to right lenght and run them trugh your original switches and dissconnect the battered original wires.

But makeing a new loom is acualy not as hard as it first might seem,as long as you have a wirediagram to look at and people have posted several good ones here in the past.

I have some laying around that I can send you if you trow me a pm with your E-mail.

cheers.

Tom
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Places to be and things to do, see you all out there!!

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  #10  
Old 8 Nov 2007
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Thumbs up Electric glue or Kiwi Cow Cockie repair?

I have welded up many gear levers, some two or three times over. If you need to get into the 'box with the lever welded on, careful use of a very small angle grinder or dremel will let you cut away the weld and still leave enough meat to weld up again.

The other fix I have used when I was a cow cockie goes thusly:

1: Remove gear lever and take out bolt

2: Put clamp end of lever in a vice and pinch the clamp up until the gap is shut.

3: Cut down gap with hacksaw thus widening the gap by about 2mm when released out of the vice (The last little bit is hard to cut as the vice will pull down onto the saw blade. I cut those edges out with the lever blade in the vice, not clamp)

4: Drill out the old bolt hole thread so you can fit a same sized, high-tensile bolt right through.

5: Tighten up the high-tensile nut and bolt really tight and this will hold for quite a while.

Regards

Nigel in NZ
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Last edited by Nigel Marx; 8 Nov 2007 at 20:37. Reason: Spelig mistaks
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  #11  
Old 9 Nov 2007
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Gear lever repair

Another method of repairing stripped gear lever splines is to fit the gear lever and tighten the bolt to hold it in place then drill into the end of the gearchange lever shaft and gear lever. This effectively creates a new master spline, drill the hole slightly smaller than the bolt or rod that you are going to insert (I've used an m 5 bolt before) then undo the clamp bolt, insert the short bolt or rod, if necessary tap it home with SMALL hammer then re-tighten the clamp bolt. I did this repair on my '77' XT500 3 years ago and it hasn't moved since. If you need a photo to explain better, please e-mail and I'll send you one. Ed.
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