my 96 xt600e gearbox was in perfect condition when i stripped it down because of a different mechanical failure :(

there has been a few crankshaft woodruff key failures on the later 4pt models :thumbdown:

my 2003 xt600e has done just around 72.000km with no enginework.

I've always heard it only was the early models.

Pigford, yep, wondering if I should tear into the TT’s engine and take a look. Not now but maybe next winter. I think the new oil line that squirts oil directly on the gearbox was introduced in 1990, in the 3TB model. So I am curious if this new oil line eliminated the fifth gear problems.

Wolfzero… thanks. I saw the pictures of the engie… Ugly stuff.

Jens, 72K? No engine work? Not even a new clutch? Wow… and I have seen in your pictures that you really use the bike… You got to love these bikes. My KTM520 lasted maybe 10K km, before the gearbox broke. It had some crankshaft problems also…

I bought it with 51xxxkm on last summer, and now its just under 72.000, so it has been used well =) But i do change oil often, and change the filter everytime. Thats a good start.

Its been riding all winters (and you can tell) but the engine is going strong, without any weird sounds, and I've even tuned it up a bit. Foamfilter, opened airbox, oversize headers and laser produro exhaust. I guess the foamfilter is adding to make the bike more reliable, as it should let less dirt through.

A guy here from Denmark bought a xt600 in the mid 80's as far as i recall, he did 250.000 of commuter km's before the piston got stock. New piston, bored and honed cylinder new bearings and rod, and cam chain and he's done 35.000km since. It costed him under 300$ in parts.

Thats what theese bikes are all about. The wont wheelie in 3rd or 4th like a pumped ktm, husqvarne og anything like that, and they are big and heavy, but they will keep on going.

This pic from todays ride says it all:

http://peecee.dk/uploads/112009/DSC00289.JPG

Mine is a 2002 600e and the gears are on their way out,anyone know who does good replacement gear cogs apart from yamaha that is!

Kenymact, sorry to hear. I have not heard of anyone supplying gears except Yamaha.

But this is new info in this thread. Since you have a 2002, obviously the “new” oil line (squirting oil on the gearbox) did not fix the problem.

The Yamaha gears are not actually as expensive as you may think - I paid about R1100 for the 2 which is around 85 Euro. This is the cost in South Africa- maybe you guys get ripped harder than we do...

I think Kenymact was after "non-Yam" gears so they last longer - more of an UPGRADE :cool4:

Any gears would be good at the moment,being new to yam xt series I,m not sure how the engine s are identified,or whet year model is which,I still need to find my eng id number but don,t know where to look as I have no manual yet.

I,ve just ordered a complete overhaul gasket set from e bay,I will order a wiseco oversize piston next and start by finding some special tools I might need like the one that holds the crank from turning,looks like a pair of mole grips with long arms and two dowels for holding stuff.......

Not sure how big I should go on the oversize piston so if any one has done it before drop me a line as all help is welcome.

I,m looking on e bay for some gear clusters but as mine is a 2002 600e model I don,t think they come up very often but if any one has sourced some from somewhere could they let me know....

Kenymact if you have the time, I think many guys on the HUBB would be most interested in a short description and some pictures of the rebuild. :thumbup1::thumbup1:

Btw, how many KM do you have on the XT?

[quote=kenymact;264654]
Not sure how big I should go on the oversize piston so if any one has done it before drop me a line as all help is welcome.
quote]

piston maximum is dictated by barrel liner size if you don't change the barrel liner and enlarge the crank case aperture 3mm oversize is the max without new liner and crankcase mods which gives you a piston of 98mm and a capacity of 635 ish cc :innocent:

i've got a high comp 98mm in my supermoto xt 600 see the thread of the same name for details :thumbup1:

Hi G600,it had 73000 kms when I picked it up but put anothe 800 riding home from the North Island of newzealand to my house in christchurch which is in the south island...