2nd gear

[adam79]

Does every year of the XS eleven model share the same 2nd gear slip? I want to buy a tranny off a 78 standard for my 79 special.

[trbig]

Every year and model of the XS and XJ have the same gears... so all have the weakness. Some never show it.. some show it in 2nd, some in 1st.. but they are the weak link when stock. If buying some, I would dremmel them before using. Since that's only going to save you a few hours by having them done beforehand.. I would skip buying the "New" gears and just fix what you have.

[Bigfoot]

I agree with trbig. If you buy used gears you should backcut them before installing. If you are going to do that, just backcut the ones that you have.

[adam79]

Im going to back cut then. So there are really no changes at all int the tranny over the years? A 78 standard will swap into an 82 special?

[mitch]

Gears

All the same unless you buy new ones ( very xspensive) Lots of info with pics on this site on how to do the fix. The newer gears are all ready backcut but for 500 bucks . @ 2 hours to do the backcutting max. You can do it we all have and i never had a tranny apart before. good luck
Doug

[bikerphil]

washer

Also, don't forget about the washer swap. I have found that this will double the life expectancy of 2nd gear.

[adam79]

Yes, this job seems very intimidating to me, so when I do it Ill be asking several questions. I found multiple step by step processes in the tech tips, so thats what Im going to follow. Is the washer swap tip in one of those?

[bikerphil]

Do a search for washer swap, something should come up. It's very simple. There is a washer on the left side of 2nd gear. When re-assembling the gears on the counter shaft, relocate the washer to the right side of 2nd gear. That's it. Everything else the same as in the diagram.

[trbig]

Here's a thread I posted a few pics on. Maybe it will help with the washer questions..


http://www.xs11.com/forum/showthread...ht=washer+swap



And yes...every bike, every model, every year XS/XJ has the same gears.


Tod

[Ivan]

I tried the washer swap on my bike when I dremeled the gears. I found that the gear woudn't completely clear when the transmission was in neutral. It was just interfering by a few thousandths, so I reverted and went with only the back cut gear. I may have done something wrong, but I don't think so. This is just a warning to make sure you check it before you reassemble it, just in case.

[trbig]

Ivan,

Sounds like your shift fork for 5th gear maybe be a bit worn or bent then? There shouldn't be any problem clearing. That washer doesn't move it much.. but every little bit SHOULD help.

The problem I have had with the washer swap, was after I put the retaining clip back in, the 2nd gear was very stiff on the shaft. I don't understand that since you are still taking up the same amount of room with the same pieces.. just in a different order. But I have never seen a problem and it will loosen back up after being run a bit.


Tod

[bikerphil]

The problem I have had with the washer swap, was after I put the retaining clip back in, the 2nd gear was very stiff on the shaft. I don't understand that since you are still taking up the same amount of room with the same pieces.. just in a different order. But I have never seen a problem and it will loosen back up after being run a bit.

I've had that problem too. It seems that the retaining clip gets distorted when being removed. That type of clip can be a pain in the arse. My solution was to straighten the clip out as best as possible and carefully re-fit. Seemed to help. Also, I had a few extra washers which I mic'd to find the thinnest one. This also helped.

[Ivan]

That could very well be Tod. Like I said it wasn't binding up at all, just the tops of the cogs were grazing the gear. I haven't had a problem since I back cut the gears though, so I am not terribly worried about it.