XT600e jumping out of 4th & 5th
 

Hi everybody,
I'm in Thailand on my way from Dubai to Perth and my bike's jumping out of 4th & 5th gear whenever I put load onto these gears.
I know 100% for sure that I'm not accidently knocking the selector with my foot.
The bike is perfectly ride-able. The only problem is 4th & 5th. They're OK on the flats above 3,500RPM but as soon as I put load onto them (like going up a hill), or drop below 3,500RPM, they jump into the gear below. I can re-select the gear easily provided I go above 3,500RPM and don't load the gear.
I've read the post here: URL="http://www.horizonsunlimited.com/hubb/yamaha-tech/gearbox-jumps-out-1st-second-26822"]http://www.horizonsunlimited.com/hubb/yamaha-tech/gearbox-jumps-out-1st-second-26822[/URL]
My bike's a 2001 XT600e with 75,000km on the clock and I suspect that I might have worn selector dogs on the gears that's causing this jumping or maybe bent / worn selector forks.
So I'm looking for advice on 2 things:
1) Does anybody think there could be another reason for the jumping?
2) The bike works fine. But with approximately 10,000km to go to Perth, should I leave it and carry on riding or should I get it fixed as soon as possible?
Thanks in advance for the help
Bruce

I agree with Mezo, this is serious. If it is a bent shift fork (selector), it could possibly be straightened if none are available where you are. If it is a dog on a gear, the gear would need replacing and the broken off part found. If you cannot get one locally, some one on here may be able to ship you one. Please post your engine serial number etc plus year model. What ever you can provide here will make it easier to get you a part provided it is not available there or you have not made other arrangements. :oops2:

None of us would like to be stranded and many will come to your rescue as best we can.

Thanks guys.
Prepared myself for having to split the engine. Not something I want to do but it needs to be done.
I'll go to Malaysia and do the work there.
I've sent enquiries to my contacts in South Africa and Dubai to see how quickly they can ship parts to KL. I also approached YAMAHA in KL but don't expect much success there.
Once I get a response, I'll need to decide if I should order parts now without knowing 100% the cause (which will mean buying parts I think I might need), or if I should find the problem after splitting the engine & then order only the part(s) I need.
It's a 2001 model XT600e engine number starts with J302E if that helps.
Thanks again - will update you (and ask for your opinions), when I receive news on the parts availability. But if you have any thoughts now, I appreciate the feedback.
Bruce

Well, best of luck and safe travels. We've got your back. It will be hard to know what to order and sure as you order in advance, what ever the problem is won't be what you ordered.... Surely a small gear or what have you won't be too expensive to ship in by air.

As you probably already know, good idea to replace some seals and all gaskets in case some are torn or worn... :mchappy::mchappy:

I also believe lots of YAMAHA parts are made in Malaysia. Figuring out where to get them in Malaysia is gonna take some work. YAMAHA in Darwin have some parts. They tell me the stuff they don't have is on a 3 week lead time from Japan. I'm waiting to hear what South Africa and Dubai's got in stock. Maybe a combination of all three is the way to avoid a 3 week wait in KL.
I looked through e-bay and trawled the web looking for immediately available parts for the XT600e. Not much out there.
Any recommendations on reliable online part suppliers?

Yamaha Malaysia
 

Check this out: Hong Leong Yamaha Motor Sdn Bhd
The same group operates Yamaha Singapore. Commonly replaced parts (like brake/speedometer cables) are usually in stock but less commonly replaced parts (like carburetor) take at least 1 month to order from Japan, at least for Yamaha Singapore, as this bike is very uncommon in Singapore. Not sure of the situation in Malaysia but no harm contacting them. Let me know if anything else.
All the best. Cheers.

Have you checked out Partzilla.com for cheap genuine OE parts?
Not sure what the shipping time would be to where you are?
Bob

Thanks everybody for the info & suggestions.
I've contacted the YAMAHA dealers in Malaysia, Indonesia & Thailand but none of them can help. Looks like the parts will come from somewhere outside the region. I'll look into the Partzilla lead now.
Thanks again & will let you know how I get on.

Just to wrap up the thread - the parts came from the US (long wait in Malaysia), pulled apart the gearbox in Kuala Lumpur. Some wear on 4th & 5th as well as the selector forks. I replaced them, together with the clutch and all's well again. Rode the 7,000km to Perth without an issue.
Thanks everybody for the advice!