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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 31 May 2012
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Tenere 1VJ front sprocket

Can anyone confirm that this is normal looking axle. I have removed fron sprocket, and I am confused why teeth on axle are narrow in the middle. Because of this front sprocket have allot of free play.
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  #2  
Old 31 May 2012
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Output shaft

Unfortunatly thats pretty knackered,not that uncommon on early xt.
Options are strip motor and replace shaft......the savage option of welding the sprocket on?....or slightly less savage,get 2 sprockets preferably unworn,turn or grind one them down to reduce its diameter so chain clears it whilst running around other sprocket,bolt pair off them together and weld,then fit to spline,check retaining plate locates in groove ok,if not reduce thickness slightly of whole assembly..hope that makes sort of sense.
My 34l has a slightly worn spline,nothing like as bad as that so I done this as a way of increasing the life of shaft as long as possible..
There maybe some other alternatives if you sat and scratched your head a bit or found one of these engineering type old boys that are just bloody clever..
Good luck
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Old 31 May 2012
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Nah.....thats proper munted.....
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Old 1 Jun 2012
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I have no idea.... But from the looks of it, the cuts/grooves are too uniform...too regular... they actually look like they were made that way.

In any case, wait for a proper answer for some of the guys who know what's what with your situation!


Vando
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  #5  
Old 1 Jun 2012
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Quote:
Originally Posted by marcm View Post
Options are strip motor and replace shaft
In 7 days I'm going on 8000km trip, so I don't have time or money for this When the time comes I'm thinking of replacing engine with 3TB one.

Quote:
Originally Posted by marcm View Post
or slightly less savage,get 2 sprockets preferably unworn,turn or grind one them down to reduce its diameter so chain clears it whilst running around other sprocket,bolt pair off them together and weld,then fit to spline,check retaining plate locates in groove ok,if not reduce thickness slightly of whole assembly..hope that makes sort of sense.
This came to my mind also. There are few mm of "healthy" shaft in the back, second sprocket could fit there. Thanks.
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Old 1 Jun 2012
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Quote:
Originally Posted by svakak View Post
In 7 days I'm going on 8000km trip, so I don't have time or money for this When the time comes I'm thinking of replacing engine with 3TB one.

8000 KMS on that shaft..... in that case get a new sprocket & weld it on, fit your 3TB engine when you get back..... I don't think there's 8000 k's left in that shaft.....
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  #7  
Old 1 Jun 2012
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Quote:
Originally Posted by G30ff View Post
8000 KMS on that shaft..... in that case get a new sprocket & weld it on, fit your 3TB engine when you get back..... I don't think there's 8000 k's left in that shaft.....
Got friend who says that he can weld and than sand welded parts to recreate teeth + he will weld two sprockets like someone above suggested. I think that will be enough.
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Old 1 Jun 2012
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suggestion?

hi i would replace the seal after you have had the welding and grinding to form new teeth done ,the heat wont do the old seal any good being so close ,just a suggestion steve
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Old 1 Jun 2012
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Originally Posted by ssbon View Post
hi i would replace the seal after you have had the welding and grinding to form new teeth done ,the heat wont do the old seal any good being so close ,just a suggestion steve
New seal already purchased I'm just hoping I got right dimension (SD 25-40-6)
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Old 2 Jun 2012
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I agree,that won,t last long and if you no time weld it on....good luck
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Old 2 Jun 2012
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Quote:
Originally Posted by svakak View Post
New seal already purchased I'm just hoping I got right dimension (SD 25-40-6)

25/40-6 sounds right, thats the one used on my '03 600e model

Good luck with the trip.
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  #12  
Old 3 Jun 2012
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After few hours of welding, grinding and blood pissing problem is, so to say, solved.
First recreate teeth on shaft by welding and grinding them



Then cut old sprocket so it will fit behind regular sprocket



Hope this will hold until I have time for proper fix.
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  #13  
Old 3 Jun 2012
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looks a good job

hi that looks like a top class bodge ,well done ,that should last till you get back have a great trip steve
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  #14  
Old 19 Aug 2012
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Just to update on situation - after 2000km on this "dual" from sprocket system I had to weld two sprockets together. Previously I had them only connected with two screws, but they are unscrewing every 300-500km. After welding two sprockets together everything worked OK for next 8000km.
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