Continuing 2nd Gear Saga

[larrydreed]

I'm doing the second gear fix. I have my gears properly beveled and now trying to put everything back together. I read all the articles in the Tech Tips; however, I can't seem to get the countershaft back into the case. Any further tips will be appreciated.
Larry/Crossville, TN

[Ken Talbot]

Larry, I can't remember if it got copied over to the forum, but check out the Reassembly Secret links from my personal webpage. Does this sound like what you're up against?

[goldcoastguy001]

If this is the first time you have done the 2nd gear fix then my best advice is slow down and take your time....the counter shaft can be a pain and can be tight to get back in.....especially if you moved the shims between the gears like i did to get a better bite on the dogs. (veiwed as if your sitting on the bike)....the left side of the counter shaft has to be inserted first then wiggle and tweeeak wiggle......swear swear....tweak.....lol.....you'll get there....but if you are on it for awhile take a rest....my first time i took ages to get the damn thing back in just to see if it would clear the other gears after moving the shims around when i was happy with the clearances i installed it again and the second time it went str8 in..


Cheers

[goldcoastguy001]

yep thats the page that i used first time round with a heap of others.....listen to Ken

[larrydreed]

Thanks guys. Encouraging to know others have had same issues. Ken, your webpage is now listed in my favorites.

[Pat Kelly]

I had a bugger of a time getting mine back in too. I had the added headache(s) of the kickstart gears (which I removed since I never kickstart it).
The other headache (literally) was the dizzyness I aquired last March. When I lay on my back the world spins and twirls for a minute or two. Add to that having the bike just inches from my nose. About half the time I got under the bike I quickly had to roll back out and throw-up (thats how dizzy I get).
The bike is back together and shifting fine. No more popping-out. I have noticed it's a bit 'notchier' now and it dosen't always want to go into neutural with the bike running.
Someday I'll see about squeezing the kickstart gears back in.

[larrydreed]

Pat,
I'm familiar with the vertigo problem. I have the same thing when I paint with a brush or roller..something about repetitive movement of hand and head. Of course, anything is tolerable to a point if it gets the XS rolling again.

[larrydreed]

My friend has a machine shop. He set my gears up on a mill and turntable. He made a 5° bevel on the dogs and slots. Being so pleased with the results, I asked him if he might be interested in doing jobs for people on this list. He said if he got enough orders, he could do both gears for somewhere under $50 per set. His expense is in setup time; therefore, the more he had to do, the less he would have to charge.
Respond to this thread if interested, and I'll pass the info on to him.