2nd Gear fix Cry for Help

[BLUEJEEPLAB]

I finally took enough time from work to get the Battle Cruiser Stripped down for the 2nd gear grind. I am down to the point of pulling the 5th gear out and have seemingly hit a rock. I have the first (left most) shift fork off of the fifth gear. According to the guidance found here on the site, the 5th gear should slide off the shaft through the bearing housing hole. It slides about a quarter inch and stops cold. The fork is clear of the gear and I can't see any obstructions.

Any ideas? It is in 4th (unless it slipped out when I was taking out the shifter pawls and shafts, but I don't think so)

[shutchis]

I'm guessing, Did you completely remove the countershaft from the tranny housing? It's a little tricky. I had to push the primary shaft gears to the right using a screwdriver to get enough clearance for the countershaft gears to swing out. It took me an hour to figure this out. When It clears, the shaft falls out, and you have the whole thing in your hands.

I tried the dremmel fix last month and it didn't work, so I order new gears from Yamaha. I should get them next week, and when I do, I'll compare the gears. See if I can determine where I went wrong.

One of the mechanics recommended replacing the shift fork. It seems this can contribute to the 2nd gear problem.

Here's my cell phone number 713-306-3494. I'll be opening up my tranny next week (for the second time in three weeks) to repair my second gear. I can take some pictures and walk you through the process.

[shutchis]

Oops, I just re-read your note; your having problems removing the 5th gear. Me too. I rotated the gears on the primary shaft so the allignment was better and out it came. See if this helps. You can still call me if that doesn't work.

[red bandit]

Seems like you'll fight it and then it comes right out.
If you get all the gears just right, the shaft will practicly fall out.

Hi shutchis, I used to live in Deer Park, 20 years ago.
Red

[BLUEJEEPLAB]

I guess I should outline how fifth came out for those who may encounter this problem.

As suggested, I wriggled and rolled the primary cluster. Hint - Don't pull the Shifter Fork Shaft all the way out, just far enough to get the first fork loose. If you pull it all the way out, you have to fight loose forks as you turn the cluster.

What eventually worked was using the gear as a slide hammer on itself. I found that as I worked it back and forth it came a little further out each time. So using my fingers as a hammer it finally sailed across the garage after about the 40th hit.

The bad news is that I need new gears... Mine are beyond cutting back.

[shutchis]

Hmm, Good and bad news, it's off (for good). I order my gears from Yamaha, and if the shipping Gods will favor a Texas Aggie, I might get them today. The Aggies won their first round in the March Madness yesterday. On a side note, I picked up an XS750 differential (rear end) this week, so I may start working on converting the XJ1100. Be sure to check that shift fork; one mechanic told me to always replace it (just to be safe).

Wow, Deer Park to Michigan...I hate snow, Love our year round riding, Hate the Summers, Love Galveston fishing. And now, Galveston has the thrid largest bike rally in America. Is it still cold up North? I'm about to ride the XJ1100 down Red Bluff to Bay Area Blvd. to work at NASA. Have a nice day and good luck on the Tranny.

[BLUEJEEPLAB]

The shift fork definately needs to be replaced. There is scoring on it that I assume was put there by the chattering when 2nd would slip. Andreas has a whole tranny, I'm hoping that between the two, I'll have all the good parts I need.

A BTW on the move the washer debate, I think that is the only reason I was not doing this repair sooner. PO had moved the washer to the Shaft Lip side, my dogs are so bad I can't believe they had any bite in the slots at all. There is hardly any where on the dogs that is square.