1st gear issue

[TopCatGr58]

Dean,

You have to remove turn signals, and side covers, gas tank, and such things, and I used a thick wool blanket to lay it down on first, but some old carpet would be just as good. I then used a long 2x4 for leverage so SWMBO could lift it while I held the front wheel and handlebars to keep them from turning/sliding. Then put it onto a metal car ramp set across the frame with a piece of wood to take the stress off of the bars, and to keep the gauges from being crushed! Also, drain or plug the oil chambers, and the final drive vent! EASY!!
T.C.

[Ken Talbot]

I believe this is TC's bike flipped on its back for transmission work:

[importeater]

transmisssion parts for 79 xs1100 special

the tranny repairs are not that hard. i had a little trouble because i didn't put it in the correct gear before flipping it over. it took me a day to tear down flip, fix, and flip back over.

I do have a complete transmission that I bought from andreas. All I did with mine was swap the entire countershaft with all the gears, after doing the 2nd gear fix to it.

So now i have a box of parts for the 79 xs 11 special transmission, as well as usable clutch plates, and brand new clutch plate screws from bike bandit.

all for 50 shipped pm or e-mail at stevencammy@yahoo.com

it's just been sitting in my garage since my bike was hit.

[goldcoastguy001]

Im not sure if i would have gone to the trouble of flipping mine over I figured it was enough to have to do the job in the first place so i tried to remove as little as possible and did it on my back looking up from the bottom with the bike on the centre stand....only took a half day from putting it on the stand to test riding it......another half day to polish the alloy bits and pretty it back up so i could go for a ride the next day.....How did youj get on Nemisis??.....

Cheers!

[TopCatGr58]

Hey Anthony,

Couple of reasons I came up with the flip technique is:
1. Easier to work on shift forks and put them back in without them falling on your face.

2. Many of us aren't as young as HobbyMan,;P, and getting on the floor, our backs, etc., isn't as easy as it used to be, so working on the bike with the Tranny 3 feet off the floor makes good sense to our joints, backs, knees, etc.!!
T.C.

PS, that wasn't my bike, it was DEO's XJ!

[goldcoastguy001]

Thats a fair comment TC.....wasnt knocking the idea.....just my 2 cents...lol.....I will suggest something i used on a different bike(not XS) when working on the crank I used a mates shed that had a strong cross beam in the roof, and used a chain and block with a strop around the steering head to lift the bike verticle....like an XSive wheel stand....lol.....worked really well......wish i had of thought of that for the 2nd gear fix on mine.....Cheers!!

[NemisusDM]

Gasket material

Hello,
I am about to do the tranny fix in the next week or so and wanted to make my own gaskets for the parts " trying to avoid gaskets in a tube".

What material should I use for the three covers and what thickness?

( cork, low temp paper, high temp 500F, Very high temp steel gasket, and thickness 1/64,1/32, 1/16, 1/8) ???

Thanks,

[HobbyMan]

yeah TC, I have done plenty of automotive work on my back. Not fun even for me. Try re gel-coating and sanding an entire 20 some ft keel of a fiberglass boat By far the most strainging thing I have ever done. regular auromotice stuff is no problem. Since it is easy enough to pull the engine, when I do it, I will just use a floor jack to get the engine out. THat will make it easy to work on. I am a little weary of flipping the whole bike over, though you have seemed to master it. MY new garage/ shed that my Dad is going to build will have a pit in it. I think I could straddle my XS perpendicularly over it to work on it. Thats all in the future.

[TopCatGr58]

Hey Nemisus,

I didn't overanalyze them so much, , just got the black or green colored stuff in a roll from local auto store. I didn't read the label, but I think the black stuff is more for oil filled chambers, but don't quote me on that. I used both on both clutch, tranny, shift lever covers with no problems, but I did also apply Yamabond to them. YMMV!
T.C.

[Snow]

IMHO, cork is *evil* - paper has always worked best for me. but YMMV...I typically get gasket sets unless they are unavailable.

[planedick]

Flipping

On Jan 18, 07 I posted a method of flipping by oneself. I don't know how to post a link here but it is in the XS/XJ discussion forum about 3 pages back. I tried tp PM you but your mailbox is full.

[NemisusDM]

shift fork?

I was tinkering around and found that my clutch slips in 5th gear. I also have to hold in the clutch for like 5 seconds to get it into second gear without grinding the gear. All else works fine but that grinding into second has me wondering if it's the shift fork or is it an after effect of a slipping clutch??

[NemisusDM]

Finally!!

Well almost.

I finally got around to doing the work and flipped the bike, removed all covers etc... I got the gears out and did all the work on the transmission except, I had not considered one thing. I purchased shift fork 1 for 2nd gear but, I hadn't considered that first gear was the one slipping as a result shift fork 3 is beat up quite a bit since, 4th gear kept slapping it silly.

Well I haven't finished makeing the gaskets for the side covers but, let's see if the fork will shift fine after back cutting the gears. I know I have to replace it but, It's gonna go to the shop for that. Turns out the actual work was pretty easy it was the flipping part that gave me trouble, it's a little hard doing it by yourself and not damageing anything.....

[NemisusDM]

While I was at it....

I also added the extra steel to the clutch basket and installed Barnett springs. In all the excitement I forgot to bend the tab on the clutch basket nut washer so I had twice as much fun installing the star plate...lol

[BLUEJEEPLAB]

Make sure that you run through the gears quite a bit when you get it all in. If you get through all five with ease, that's a good indication that you got it together good. Since you are flipped, you also have the advantage to look down and see where any binding is happening.

My 2nd was having trouble at first (about the 1st 200 miles) where if I didn't hit it hard, it slipped into false neutral. That went away on it's own.

Keep at it.