Iv been in your shoes many times...

usually when you've just spent £300 on a topend rebuild, the gearbox and clutch go next...

You fix them and then the main bearings start going

You fix them and then the big end goes and the suspension starts giving out..


You end up building a brandnew bikes at 3x the cost of getting a good one.

If you enjoy the spanner time and want to learn then go for it.. be prepared for irritation and bills though.

__________________
Did some trips.
Rode some bikes.
Fix them for a living.
Can't say anymore.

It's fair to say that my current XT 600e has done a lot of work.
The guy I bought it off had done a trip to Cape York (nothern tip of Australia) I don't believe he treated the bike well therefore when he arrived back in the big city it was necessary to undertake considerable repairs.
He showed me an long list of reciepts and spoke of reboring, head reconditioning, bearing and gear changes etc. None the less the bike looked nasty.
I didn't necessarily believe the previous owner had actually done all the work mentioned but as I bought the bike for a bargain price ($1750.00 in 2000 so 7 years ago, the bike was only 4 years old at the time)
Soon after buying the bike it developed a very nasty bottom end knock. This ended up being a very poorly fitted keyway on the counterbalance shaft. I filed the keyways on both shaft and gear, made a new oversize key and used a healthy volume of loctite and away I went.
7 years on and about 50000KM the bike developed another very nasty bang (not really a knock). I expected this was bigend as I couldn't confirm what was repaired or the workmanship involved. If the key incident was and guide the workmanship was poor.
So the bike was stripped.
To my surprise the head gasket was blown which would account for the bang.
The 2 piston compression rings were aligned which would acount for the exessive blowpast and lack of compression.
The previous owner had rebored it, 1mm over, it truely does appear he did perform much of the work he mentioned, unfortunatly the workmanship is the primary issue, eg. volumes of silicon rather than "O" rings and gaskets..

The bottom end is tidy, There are 2 concerns I have,
1. lateral movement in the bigend is out of tolerance..
2. The bike would occasionally jump from 1st gear to neutral or second to neutral.
The gearbox is pandoras box to me. I havn't split the case yet.
Is it worth delving into the gearbox or could there be someother more obvious issue causing the bike to jump out of gear. (Should I start a thread for this?)

Any advice would be much appreciated.

New thread.. hmm, i suggest a new forum

__________________
Did some trips.
Rode some bikes.
Fix them for a living.
Can't say anymore.

New forum!
Do you have one in mind

I didnt mean join a new forum, but start one .. for your problem..

Was a joke.. jeeeeeez !!

__________________
Did some trips.
Rode some bikes.
Fix them for a living.
Can't say anymore.

G-day Ted
I must say I wasn't sure
I did start a new thread, hope fully you or someone has advice on that pandoras box..