Help re-assembling trans

[Jean Luc]

I have dis-assembled my transmission to do the "Black and Decker Fix" to first gear. I am now at the point of putting the main shaft back into the transmission.

I need to know the trick to get the shaft back into the proper position. The middle drive gear and first keep getting hung up. I know there is a trick to putting the shaft in, but after 3 hours, I am out of ideas.

HELP

[xssiveone]

Jean, check out Ken Talbot's page at:
http://www.rctvonline.net/xs11/

Very informative and has lots of pics on this very subject.

[Jean Luc]

Interesting,

I followed Ken Talbot's instructions at http://www.rctvonline.net/xs11/secon...ddendum5.HTML.

After about ten minutes (and about a dozen four letter words) the transmission is reassembled.

Wow, it even spins freely and even shifts. Thanks for the quick response. The pictures really helped me visualize the entire process.

[Ken Talbot]

Hmm. Perhaps you could send me the words and correct sequencing so I could add them to the tips page? Might save the next person a few minutes...

[TopCatGr58]

The right words

Hey there Ken and Jean Luc,
I remember the first time I did this and I, too, had quite a few choice words....but then I found out the problem, it's the shift fork shaft, that little flat spot on it that allows the first gear and the other gear to spin without hitting the fork shaft, if that flat spot gets turned so that the flat surface is NOT facing the gears, then the gears WON'T fit or slide into place. So, IMHO, I would suggest that that is the 'critical' step in the reassembly process, once I realized that, and on the 2nd tranny I worked on, the gears fell right into place lickity split!

[Jerry]

Sure glas this thread started again, as I'll be doing my 2nd gear fix in a week or two and have just reviewed all the articles....

Trouble is the weather is still pretty decent. Took a small jaunt today (60 miles or so) and the cottonwooeds in the creek bottoms are still a nice golden yellow. Can't tie up the bike yet, can I?

[Jean Luc]

Jerry,

Should I send you the list of words directly?

[TopCatGr58]

Originally posted by Jerry
Sure glas this thread started again, as I'll be doing my 2nd gear fix in a week or two and have just reviewed all the articles....

Trouble is the weather is still pretty decent. Took a small jaunt today (60 miles or so) and the cottonwooeds in the creek bottoms are still a nice golden yellow. Can't tie up the bike yet, can I?

Hey there Jerry,

Did you see the diagram I provided in the other similar thread in response to another poster's request for info. Even though your Second gear may be acting up, your first gear proabably won't be far behind, I'd take a good close look at that one as well. Jean Luc has a 82XJ, and I worked on the same model this last summer, the one I did had 1st gear as the culprit, but second was looking quite worn, so I did both since I had the tranny parts out anyways. Could save you some aggravation a few years down the road, just not sure why some folks have 2nd gear that acts up first, whereas others have 1st gear. My 81SH had 1st gear give out first, then 2nd followed quickly thereafter causing my parking it for 9 years until I found the LIST/web site and all the references for the repair/fix process!

Good luck when you finally decide to tear it down, BTW, did you see the tip about turning the bike upside down to work on it instead of lying on your back underneath it, I think it's the better way to do it....IMHO.

[Jerry]

Saw all the posts, both on the old Yahoo list, this forum, and off-site Tech Tips. Started getting parts together last year, had the gears undercut for the 2nd spacer, which was obtained from a donor '79 standard. Gears were from same bike, look perfect. Have all the Yamaha gaskets and such. Plan to lift the front end of the bike up in the air with a come-a-long, leave rear tire on the ground. Kept most of the tranny parts from the donor bike, so if there is shift cam, first gear, or other problems I hope to have the parts to replace any damaged ones.

Depends on weather...as long as it stays decent I prefer to ride over wrenching, particularly on tranny, as I've not done any transmission work before and am nervous about it. Besides, have rides planned for next couple weekends, so it may be December before I start the project. Hope I can get it done in one day. Since I don't have to take time to rework the gears, should take (I hope) about 6 - 8 hours.

Probably don't need the list of words...have owned old bikes and cars since my high school days, when I started with a '46 Plymouth and a '59 Austin Healy Sprite, later was complete with Lucas electronics. Had a '45 HD45 at about the same time, didn't like it much and soon sold it. Currently reworking a '77 Honda CB550F (now running!) and have a '69 Honda Trail 90 waiting for work. To many projects, not enough time and money.....and a few extra words.......

Other than 2nd gear and replacing the fuse block, the XJ has proven to be a very reliable bike and I don't hesitate taking it out on long trips.

[Jean Luc]

It Lives!

I tightened the last bolt tonight, fired 'er up and took a quick blast up and down the street. Keep in mind that this is the first time I have ridden my XJ with a working first gear. Wow. I am looking forward to the warm days of next spring...

Looking back the process was not that hard for a first time transmission mechanic. I couldn't have done it without all of your help (especially topcat). The documentation available on this site is top-notch.

THANKS

[mitch]

jerry

jerry i did my tranny 2 wks ago i tried the chain falls and after much aggervation i turned the bike upside down much much easier trust me thats the way to go thxs ,,,doug