I might give this option a try. Something along this way of getting the gears to fit. I know a good fabrication place in town that'll help me out with it. http://www.horizonsunlimited.com/hub...solution-80123

I would just buy a good used one from the states, they seem to have had an easier life than aussie ones.

Here`s one for $30 bucks.

Mezo.

Most of the engines I've had apart here have had shot 5th gears , all spalled/chipped . I'm just not sure if it's from running too high gear at too low rpm and the "chugging" that the engines do it that situation or if it's from oil cavitation and what that does to surfaces . 3 of the newer 3tb's I've had now have been the same condition , even one at 11K miles showed small chips and the beginings of the issue. so doing all that work to use the newer gears isn't a foolproof solution.

I also saw this on my XL6 btw , though not as bad . DR650's get it badly on 5th and 3rd usually , sometimes ending in destroyed case. Even the aftermarket replacements with more ideal heat treatments are showing the same thing .

Get one made, there are fabricators who will make the gear for you. where are you located? there is a guy having 3 made in Australia as we speak,one of which is for me.

Im in Northern NSW, who does that sort of fabrication and is it pricy?

I got onto the one I'm having made through a post on the Tenere Tragics feces book page, it's costing about $350, however last week I was in my local Yamaha dealer getting some reasonably priced parts for my 39E when the guy behind the counter gave me info on a gear cutting workshop called Coljen, (Heidelberg, Melbourne) who was currently making lots of gears for Suzuki dealers for DRs, they make lots of bike gears and can make the 5th Pinnion.
I rang them and they may be a bit cheeper than what i'm paying, but they would need a sample. the gear I'm having made is being made from some superior metal, apparently.

i'm interested in Moorespeed's gears, but I don't think they'll work in my early bikes

Hi Jesse,

I have had this problem in my 1984 XT600.

I too used the above article as a good starting point for solving this problem.

I have engineered my own solution, which I am near to installing and running for the first time in a few weeks.

Please, anyone, correct me if I'm wrong but i believe the 5th gears from a 2JT model are a direct fit replacement for the earlier 5th gears. Yes they have a different number of teeth than the originals (meaning they have to be replaced as a pair) but I think physically they are the same size as the earlier 5th gears and can still be sourced from MegaZip: OEM Motorcycle Parts, ATV Parts, Marine Parts, Automobile Parts.

I went for fitting the upgraded 3YF 5th gears into my gearbox, which meant thinning of the 2nd gear on the output shaft.

I guess this is a gamble, and many may not recommend this, but time will tell if this is a mistake I have made and will learn the hard way, or if all will be OK! I used a local machine shop to flat grind the gears to the required dimensions, and modified two 27mm x 0.8mm bearing shim washers to become spacers where required.

I'm happy to send over my mechanical drawings which detail my solution, and can report back in a month or so how it goes.

So far, with the gearshafts installed in the engine casings, my modifications work nicely - i.e. all gears fit, and select smoothly. But until I start putting torque through the modified 2nd gear, I won't know how it'll hold up!

Many thanks to pete_j for his work and advice!

hope i am not disappointing anyone, but just opened a 3yf motor yesterday, and 5th was shot too. badly.

i been searching quite a bit into that as i need the shorter ratio 5th for my road racer. Nova in uk used to make them, but are out of stock.... actually if there's a minimum order of five, they will redo.

so if anybody is interested in a shorter gear 5th for 3yf's, which makes less of a gap from 4th to 5th as well as logs the engine less, you are welcome to pm me....

now, the only thing that surpises me is people saying a 3yf (xtz660) 5th pair will work in a 600.... dont know the 600 that well, but i thought the 5th sits in a 600 next to 1st, in the 3yf its on the opposite side. i might be wrong of course.

looked a bit into atv gearsets, just from pics the shaft splines look different

I have just bought a gearbox out of a 4gv engine, 1993-97. I am going to transfer the gears onto the older style shafts from the tt600 '83. I have compared the lengths of the gears with a set of calipers, everything looks like it will fit up. I will have to get the 2nd wheel gear machined a couple mm thiner to fit in the case with the thrust washer from the '83 setup instead of the spacer from the 4gv. Hopefully itll all fit. A copy of your mechanical drawings would be very helpful heffho83'.

Hi Turbo,

Check out the transmission parts diagrams for a 1996 XT600E 4PT model on and parts suppliers website.

3YF-17151-01-00 5th pinion gear and 3YF-17251-01-00 5th gear wheel, are the wider gears (i.e. wider than pre 1996 models, so not a straight swap).

5th gears sit between 3rd and 2nd gears on the shafts and are the same as those used in a XTZ660

Wish I'd discovered this Nova company you mentioned before I started my gearbox mods! I looked into getting custom cut 5th gears and got quoted a small fortune!

indeed, my bad... it's in the newer 4 valve 660 that the 5th gear was moved next to 1st.

better then! means that between 600 and 660 owners we could more easily gather 5 orders....

seriously, anyone interested?

Hello again.

I dont want to open a new thread so I`ll post here...

I have a 1992 xt600e 3tb

I am having some issues with my gearbox, well, actually only the 3rd and 5th gear. First 2nd and 4th are normal, but the 3rd and 5th gear give out some strange sound, like something is grinding togetger, besides the sound it works fine, no lack of power or jumping out of gear... The bike has been laying around for about 6 years, and when I got it, i stripped it to bolts and nuts to inspect all the interneals. I know I changed some gears but I`m not sure which one this was about two years ago, but I only rode it for couple of miles and I dont really remember if that sound was there, as the exhaust was extremley loud

I now had enough time, to bring it back to life, new tyres, spokes, front and back suspenssion...

So, any ideas about that sound, it is exactly the same in 5th and in 3rd, so I dont think they are both worn out, or are they?

Here is a video of the sounds...

https://www.youtube.com/watch?v=waSW0osW2HY