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The TTR250 FAQ web pages -> TTR250 -> Repairs and maintenance -> 6th gear wear and solutions
Post Info TOPIC: 6th gear wear and solutions
mossproof


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6th gear wear and solutions
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In rebuilding my 325 into a 350 as it has finally succumbed to the dreaded barrel weep, I have found the 6th gear in the transmission is quite badly pitted on the tooth surface. I know this is an issue with the xt/tt 600 engines (top gear being 5th in these) but didn't realise it was much of a problem on our engines, except in motors that do a lot of highway in top.

Anyway, the gear in question has been discontinued. Searching Japan has turned up nothing, various Australian websites that still list stock just don't seem to want to talk to a Pom, and the US just doesn't want to ship to the UK, before I even get to searching a particular part! It is part number 4GY-17161-01. The corresponding gear on the countershaft, 4GY-17261-01 does not seem to wear, and is still available!

I am investigating having a batch made (like the XT600 guys do) and wondered if anyone out there would be interested in  buying one if they were available (to help me decide on batch size/demand)

I have a used spare transmission in reasonable condition to get me rolling again, but buying from breakers with poor pictures of gear tooth condition is a lottery and I want to future-proof my bike a bit. 

Anybody interested?



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KiwiJeff


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Hi Simon,
I have also found this situation, where Aussie Stockists won’t sell, or send outside Aussie so I’ve had Aussie Mates buy whatever I want and send it to me in New Zealand and we sort out the payment later.
I can have a go on your behalf if you like as they might sell to a Kiwi.
Of course it would be easier/quicker if one of the Aussie Subscribers to this Totally TTR’s Website, buys it, on your behalf and sends it to you but if you want me to have a go just let me know.
The Website that I seem to have found it on it:
YAMAHAPARTSONLINE.COM.AU
Cheers
Jeff

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mossproof


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Hi Jeff,
Yes, yampartsonline is the main website I've found too. I haven't tried phoning them, but they don't respond to my emails. Thanks for your kind offer, if nobody more "local" will have a go for me I'll take you up on it. Now the engine is going back together with a reasonable used part I'm not in a big rush, and I don't really hold out much hope that there is anyone holding stock - certainly UK main dealers would buy direct from Japan on demand, and Japan has run out.
Cheers,
Simon.

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Ttboof


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I found partzilla in the US send without question, it's all online and easy to use. also, much cheaper than (got all my sprag clutch stuff there) Yamaha dealers for genuine parts, my gearbox went bang and i was able to buy a complete set of internals on eBay .  the problem i feel is the lack of a cush drive, I had an XT 550 with a cush drive and got 98000 ks before top gear stated playing up the TTR went 80000ks mainly dirt though.



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mossproof


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Hi Les,
Unfortunately Partzilla don't list it, although they do seem to list most of the others in the box. Obviously 6th is the most frequently worn out and has sold out.
I fitted a cush hub some years ago, but I don't know if the wear occurred before that - I've not looked that deeply into this motor before. Done about 14000 miles on it myself, plenty of highway, but previous history unknown.
Out of interest, what was your "bang"? Catastrophic failure or nasty rumbling noises?

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Ttboof


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the bang was just that riding along and the gearbox went bang and locked up i was on dirt down shifting so it was a slide to a stop fortunately, the gears were damaged and shift mec was stuffed. the cases were ok but there was a lot of damage to the internals i was unable to find the actual cause . My 550 did the same but punched a hole through the back of the case.

the secondhand internals have now been in a few years with no problems, i was surprised how easy it was to fix (replaced all the bearings while i was in there)



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IOWChris


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I’ve asked my mate who runs a Yam dealership and he can’t get them either. Only suggestion he had was kedo.de, who don’t seem to have it

Hope you find one, and I also hope mine doesn’t break!

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AussieChookchaser


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Is this the part you are looing for? www.ebay.com.au/itm/263486703310%3AAQALAAAA0GfYFPkwiKCW4ZNSs2u11xAq%2FaigcyztwbIxFp23MSBtHai%2B8QPHeOH9lC0ik5aYCyjqySpV51qiE41nh%2FmG0BoyRO78bs2LD9S6Dx89W1ApK3ceS3w4%2F%2BeWLU%2BqM303XEtJVQQHJY9lNUv6gDMbg%2Fg3p2M9rBr5TXO2iFHX7LkPD5XabMqykCQvzy%2FKnw8HtgHa9L77xR5w5Ohza6--ZNrj6oD35ZJIySSTXN04cPDoaoxLDKUFGW1JpnGVpwU%2FKjNkJ%2BjhAIIcpStxBOZ0H08%3D%7Ctkp%3ABk9SR-zUldr1Zw

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mossproof


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Hi Jason,
No, that's the opposing one on the countershaft that doesn't seem to wear, but thanks for looking (and thanks Chris).
The general consensus in xt600 groups is just use good synthetic oils (Motul 7100 for eg) and don't ride hard in top (easier said than done!!)


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AussieChookchaser


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No problems at all. Is the word on the street full synthetic for the TTR, if so I will switch from semi synthetic. I will just buy the oil when it is on sale.

 



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IOWChris


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There is a full gearbox on eBay for 130 quid, gears look in decent condition. Bit wasteful to buy a full box for one gear but it’s not super expensive

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mossproof


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If the gears are in reasonable nick it's worth that for a spare if you're into the bike long term. New individual 6th pinions made specially likely to end up £100 each!

I think synthetic oil is the go if you're "adventure biking" just for insurance sake.

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