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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 26 Dec 2006
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Question XT600e Gear Lever

I've not found the XT gear lever to be a particularly reliable part - unlike the rest of the bike: Within hours of tightening the pinch bolt it's loose on the splines of the gear shaft and eventually I'm sure that the splines will get damaged. The problem seems to be the design (I'm on my 3rd) and although they do get severely abused (hitting ruts/rocks offroad), my Montesa does the same stuff and has a perfectly tight lever.

Question are the TT / TTR levers any better designed/constructed and will they fit or has anyone modded or used anything else?

Thanks Bish
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  #2  
Old 26 Dec 2006
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XT Gear Lever?

I have a XT600 84 model, and have a gear lever off a TT600 84 model. Works good. Found on E-bay. I just put a longer bolt in and double nut the the bolt. Hope this helps. Hi, To everybody, first post to The HUBB!
BIG ED XT&TT 600 FAN!!
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  #3  
Old 27 Dec 2006
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Just use a longer bolt and a nylock nut or two.
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  #4  
Old 27 Dec 2006
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Unhappy XT600e Gear Lever

Hi - Thanks for the advice... I actually do the longer bolt with the nut on the end trick and loctite it all up - the bolt's never loose. The issue seems to be the rather spindly spline part of the gear lever (and perhaps that it's steel? the alloy ones get pinched harder by the bolt). If there was room I'd tap the threads up a size and be able to torque it harder with a bigger nut & bolt...

I'll have to suss out some other Yam offroad models and see if I can get a more robust lever off another model that will fit.
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  #5  
Old 27 Dec 2006
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Wink

try getting a hacksaw and sawing through the slot in the gear lever to widen it a bit. If, whenever you tighten the bolt up, the slot is completely closed, the gear lever might not be clamping fully on the shaft. \Squeeze the slot closed in a vice and saw through, then when you loosen the vice, the slot should be a fair bit wider and will clamp securely on the shaft This worked for me as mine always seemed slack.
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  #6  
Old 28 Dec 2006
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sounds like the gear lever has vibrated and worn a bit on the splines, hopefully the lever is softer than the shaft and thats not worn! you could try the old windscreen wiper trick of sandwiching a bit of tinfoil in there?
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Old 1 Jan 2007
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Thumbs up XT600e

Thanks - I'll try widening the slot trick to get the clamp pinched up more, as despite only put it back on a few days ago, a days trail riding has clobbered it.
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  #8  
Old 20 Jan 2007
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Thumbs up XT600E Gear Lever Fix

Thanks gavxt600e - the widening of the pinch by hacksawing worked a treat. After refitting and torquing it up about 3 times (after it bashing a rock or 2 trail riding!) and the lever is at last on the splines like a limpet... now only if Yamaha had thought of that!
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  #9  
Old 16 Apr 2010
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Gear Shift Grub Screw Fix

Try this instead of stretching and stripping threads, hack sawing out gaps, rock bashing and sewing needle insertion! Weld on an M10 or 3/8" nut on the boss, the lever boss is also tapped to match whatever toothed grub screw you can get! Never slips! Drill or file a little seat for the grub screw teeth in the shaft as well. Another Aussie made and tested design.

Cheers.
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XT600e Gear Lever-loose-srew-lined-up.jpg  

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  #10  
Old 31 Oct 2010
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I am suffering the same problem. I have a bad vibe the grooves on the spline are worn as I have tried three gear levers (my original bush-bashed one, a steel XT600 one and an alloy XT600 one) and they are all loose, the last two considerably loose. I hacksawed the old bush bashed one and still no go.

I don't quite understand the grub-screw arrangement in the last post, so if anyone could shed some light it would be appreciated.

I am thinking I might have to get a sleeve heated and put over the spline and then re-grooved. Any ideas?

Last edited by Double Supercool; 1 Nov 2010 at 09:49. Reason: My grammar sucks
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Old 1 Nov 2010
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I got this!



[url=http://www.motoclasse.com/index.php?mod=catalog&action=viewProduct&product_i d=1769]Motoclasse | Acess

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  #12  
Old 1 Nov 2010
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I will check it out. If nothing else, I will have a large collection of levers!
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