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**mitch** · 06-06-2003, 11:37 AM

dont remove the engine

drain all fluids and remove the battery, then remove the mirrors turn your bike up side down and remove the bottom pan much easier to work on and about 3 hrs less work . i didnt need any special tools when i did mine good luck Doug M

**Mike Hart** · 06-06-2003, 11:41 AM

Not sure which manual you are looking at, but some of them say you need to pull the engine and split the cases, and that is flat not true.

Have you looked at the Repairs/Transmission forum?

Good luck!

**Jerry** · 06-07-2003, 09:29 AM

Mark:

I did the "2nd gear fis" on my XJ a couple months ago. Had put it off for quite a while as I was apprehensive about tearing open the transmission. It wasn't that bad.

I did the repair the old-fashioned way, with the bike on the center stand. Reason: I have a full Windjammer set-up and removing everything to turn the bike over just wasn't an option. Rest assured you can work on the bike in the normal upright position.

Special tools.......
Not many are needed, and most can be used for other work. You should get a set of metric Allen wrenches. I bought a set mounted in sockets, but there are one or two bolts where they won't fit so I still needed the regular ones as well. If you have the budget, a set of long wrenches with the "T" handle ends would be great to have. You will need an Allen wrench to remove the exhaust system nuts on the headers as well as the oil pan and side covers bolts.

Other special tool is a Torex T-30 wrench or socket-mounted bit. I went for a set of the socket-mounted wrenches, cost was around $12.00. You only need the T-30 for 3 bolts, but there is no substitute for having the right tool for this job.

An optional tool is a "C-Clip" removal tool. This makes removing the clip that holds the 2nd gear on the shaft a bit easier, but the clip can be removed using a couple smaller screw drivers. Tool looks a bit like a pliers, but expands when you squeeze the handles opening up the clip for removal.

One note on the XJ process. The XJ has an oil level sensor in the pan that XS models do not have. This sensor can be very difficult to remove. I left mine in place, which means the oil pan must be left under the bike (I proped mine up on the center stand) while the work goes on. I would recommend cutting the wire to the sensor and installing male-female ends to make the connection easier, or plan on repairing the wire once you have the pan back in place. Or do as I did, and just work around it, but it is more of a pain to keep the wire attached. And no, there is no local connector for this wire; it runs up under the gas tank to a connector there.

If yu can find someone local who has done the work before it would help make the job go faster, but you can do it yourself if you need to. Just be methodical, read the various aricles in the Tech Tips section, and keep things clean. It may take you several hours but it really is not difficult, just time consuming. Oh, and keep track of which shift forks go where. I didn't and had to figure out which one was #1 and which was #3. #2 is pretty obvious. Getting the forks back in is the most troublesome part of the job, requires some juggling of parts/pieces to do but you will eventually get them back in. This where having the bike upside down or the engine out of the frame makes the most difference, but can be done the old fashioned way if need be.

Good luck!

**Jerry** · 06-07-2003, 09:50 AM

Forgot to note...

Best source for ransmission repair notes is Ken Talbot's page at:

http://www.rctvonline.net/xs11/

You can find this page by going to the Off Site pages in the Tech Tips section of XS11.com. The Tech Tips link is at the left side of your screen.

**marker2001** · 06-09-2003, 07:33 PM

Thanks all - the advice was very helpful.

The bike is upside down thanks to a strong neighbor. On the '82 the bars are 2-piece and come apart easily

It turns out that I have two bent forks, AND the infamous 2nd gear problem, 1st gear seems to have the same type of wear also so I'll dremel it down too.

If anyone needs pics of what parts look like worn - including 2nd gear, give me a shout.

Once again - Thanks - Wouldn't have done it without your help.

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