Not another gearbox thread?

[Richthofen]

Hi all!

New to the forum, sort of new to the Tenere (660 -91), not new to yamaha's or bikes in general.

I did the search and spent a few hours reading about the dreaded gearbox of the XT deriveved block.

So, simce I am committing the cardinal sin of starting a thread about something that has been mentioned before in some hidden part of the dark web I will pay my dues by at least giving some background info on the bike in question.

It is mint, or at least so I thought when I loaded it on to the back of my pick up. All for one small thing. It ran a little rough and it popped through the exhaust.
After some breif trouble shooting I concluded that it had a vacuum leak in the right carb butterfly valve. Took it apart and found that attempts had been made to seal said leak. The V-ring had been replaced by double helpings of orings and the shaft itself was very worn. Idle screw turned all the way out still resulted in 2k rpm idle.

After some consideration I pulled the trigger on a raptor carb swap. After 50 times tank and carb on an off the bike now runs awesome. Power wheelies with a full tank. Outstanding throttle response, free revving. Put succintly, runs like something from this millennium rather than the choked up thing that once left the factory. It is a dream to ride, we have really bonded.

I always ride with earplugs but the 5th gear whine has still made itself known over the drone of the YZF450 pro circuit pipe.

I have some time an emotional capital invested in the bike and I love riding the thing so much. So I want to fix it.

What are ppl doing these days to get this sorted? Pestering Yamaha to start making parts again?

Will the shafts from the newer FI 660's fit?

Does anyone weld and reface the gears?

All ideas within the realms of decency wellcome!

Cheers!

Chris

[jibber]

Keep your eyes open for a decent second hand set, new stuff still pops up now and then as well.......ebay
What's the part numbers?

[donnybach]

Theres always a donor MZ baggy, engine or damaged full bike?

[Richthofen]

Thanks for the suggestions!

3YF172510000
3YF171510000

Those are the parts numbers. I will continue scouring the ebays for a gear set.

I found 2 complete axles for an XT660Z so I thought I might take a stab in the dark and see if they would fit.

If I do I will report back.

Onwards and upwards!

[Richthofen]

To follow up on this and for the benefit of anyone having gearbox issues in the future...

This guy has the gears:

https://www.motoritz.de/

I ended up rebuilding the engine with a good set of shafts of ebay but I inquired about them with motoritz and he verified that they have the gears and at a reasonable (similar to OEM) price.