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.

LinkBack Thread Tools Display Modes
Old 28 Oct 2007
Contributing Member
Veteran HUBBer
Join Date: Mar 2003
Location: London,England
Posts: 353
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?
Reply With Quote
Old 28 Oct 2007
Registered Users
Veteran HUBBer
Join Date: Jun 2007
Location: Ripley, Derbyshire
Posts: 375
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.
Reply With Quote
Old 28 Oct 2007
Registered Users
Veteran HUBBer
Join Date: Jun 2007
Location: Ripley, Derbyshire
Posts: 375
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.
Reply With Quote
Old 7 Nov 2007
Registered Users
Veteran HUBBer
Join Date: Aug 2007
Location: Sax, Spain
Posts: 919
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!
Reply With Quote
Old 7 Nov 2007
Registered Users
Veteran HUBBer
Join Date: Jun 2007
Location: Ripley, Derbyshire
Posts: 375

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
Reply With Quote
Old 7 Nov 2007
Registered Users
Veteran HUBBer
Join Date: Aug 2007
Location: Sax, Spain
Posts: 919
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?
Reply With Quote
Old 7 Nov 2007
Registered Users
Veteran HUBBer
Join Date: Mar 2007
Location: UK
Posts: 3,337
Wiring loom

You're going to make one then, from scratch?
Reply With Quote
Old 7 Nov 2007
Registered Users
Veteran HUBBer
Join Date: Aug 2007
Location: Sax, Spain
Posts: 919
may have to.........

not looking forward to it I can tell you.
Reply With Quote
Old 8 Nov 2007
tomwest's Avatar
Registered Users
Veteran HUBBer
Join Date: Sep 2006
Location: At the moment:Zanzibar
Posts: 117
universal wire harness


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.


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


Reply With Quote
Old 8 Nov 2007
Nigel Marx's Avatar
Super Moderator
Veteran HUBBer
Join Date: Oct 2000
Location: South Island, New Zealand
Posts: 755
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.


Nigel in NZ
The mouth of a perfectly contented man is filled with . -- 2200 BC Egyptian inscription

Last edited by Nigel Marx; 8 Nov 2007 at 20:37. Reason: Spelig mistaks
Reply With Quote
Old 9 Nov 2007
Registered Users
New on the HUBB
Join Date: Nov 2007
Location: Somerset, UK
Posts: 3
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.
Reply With Quote

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
XT600e Gear Lever mbishop Yamaha Tech 11 1 Nov 2010 07:34
Mesh Riding Gear - looking for opinions... davidmc Camping Equipment and all Clothing 22 4 Sep 2005 16:24
leaving gear safe with the bike fireboomer TRAVEL Hints and Tips 3 3 Oct 2004 21:02
Gear Lever - Fiche? & Any uprated ones available? mbishop Yamaha Tech 1 18 Mar 2003 14:42
Is my gear too basic? Mel D Photo Forum 4 16 Nov 2002 17:03


NEW! HU 2015 Motorcycle Adventure Travel Calendar is now available! Get your copy now for some terrific travel inspiration!

HUGE, 11.5 x 16.5 inches, beautifully printed in Germany on top quality stock! Photos are the winning images from over 600 entries in the 9th Annual HU Photo Contest!

Horizons Unlimited 2015 Motorcycle Adventure Travel Calendar.

"The calendar is magnificent!"

"I just wanted to say how much I'm loving the new, larger calendar!"

We share the profit with the winning photographers. YOU could be in the HU Calendar too - enter here!

HU DVD Autumn Special!

Take 40% off Road Heroes Part 1 until October 31 only!

Road Heroes features tales of adventure, joy and sheer terror by veteran travellers Peter and Kay Forwood (193 countries two-up on a Harley); Dr. Greg Frazier (5 times RTW); Tiffany Coates (RTW solo female); and Rene Cormier (University of Gravel Roads).

The first in an exciting new series, Road Heroes features tales of adventure, joy and sheer terror by veteran travellers."Inspiring and hilarious!"

"I loved watching this DVD!"

"Lots of amazing stories and even more amazing photographs, it's great fun and very inspirational."

"Wonderful entertainment!"

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

Scottoiler automatic chain oilers. The most important accessory for your next motorcycle adventure!

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


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 06:04.