Help Poor Trbig!!

[trbig]

The gears move apart about a half inch or so when disengaged, so that 1mm won't have anything to do with that.

Tod

[trbig]

HELP!!!

I need a favor from anyone who has a set of tranny gears out and available. I am re-installing the drive axle with the gears after fixing them, and the parts list and the book show a circlip between the middle drive gear and the bearing/housing. I don't remember taking one off of here and I can't find one. I even had another set of gears with the bolt and washer in the shaft on that end to keep all the parts together and that one didn't have the circlip either. Is it supposed to?? This is going to hold me up if it does.

I tried putting a circlip on there that kind of fits from another shaft from a parts motor.. but it doesn't seem to extend far enough through the housing that way??


Tod

[TopCatGr58]

Hey Tod,

IIRC there isn't any C-clip on the end of the countershaft where the middle driven gear and 1st slide onto the shaft. That C-clip in part of the Engine CASE that's holding the bearing into the engine case. I think if you'll look at the bearing in the case you'll find that C-clip already in the case.....again....IIRC!
Yeah, the fiche is a bit misleading, cause they don't show the ghost image of the engine case, just the bearing and the gears and shaft!

T.C.

[trbig]

Thank you TC... thought I was going crazy!! The weird thing is that there is a slot on that shaft where one could go.


Tod

[TopCatGr58]

Also, just looked again at the fiche, and the 2 c-clips that ARE on the shaft on both sides of the 4th gear wheel are a different part # from the one on the bearing. The C-clip on the bearing also just looks much larger than the ones for the shaft. Glad to help, but would be nice for others that have done the repair to chime in on whether they remembered a C-clip on the end, but I'm fairly sure that when when I pulled the shaft out that the middle driven gear and 4th gear just kinda slid off the end of the shaft.

I vaguely remember removing 1 C-clip to get the 4th gear wheel off, but left the one securing 3rd and 2nd on the shaft. This old photo shows the C-clip groove a few inches up from the end, but it's not very good or clear or big enough to reveal any groove near the end!?

T.C.

[trbig]

Yup, there's a pain in the butt spring clip between 2nd and 5th, then there's a circlip between 1st and 4th. It's the middle drive gear and 1st that fall off one end, and 5th on the other. There is a groove there in the end of the shaft on the middle gear side... but it didn't fit right when I put on ethere. I took them all off and ground on EVERYTHING! lol. (Except the middle drive gear) But all dogs and all gears got sharpened up and MIC'd to within .01mm.


Anyway... off to do more work. Thanks again.

Tod

[trbig]

So here's the deal. Before reading any further... remember this is an XJ. I slapped another motor together and went to John and Kat's house this weekend. I thought it just needed a carb synch. When we tried that it just got worse. The vacuum on the carbs is very little... only @ 5mb, but they were all pretty close together.... less than .25mb. It idles OK, but under accel, it is VERY sluggish with no power whatsoever and starts missing and popping and mainly running on just 2 cylinders (3&4)... which would lead you to think carbs. Under hard accel and rpm's above 6500, all cylinders fire well. We cleaned the carbs a couple times and nothing is plugged.. paying extra attention to the pilot circuit. We also adjusted all carbs evenly to 23mm with no change in performance. All carbs are getting fuel and checking fuel levels with clear line with the carbs on shows correct level.

I went to check compression thinking that had to be the problem... but all the cylinders were fine. So I thought possibly the boost sensor. Replaced that and no change. All I can think of doing next is checking the timing one more time at the cams. I will take the valve cover off tomorrow and check that.

These carbs, head and cams, and coils all came straight off another motor that ran and responded great... it just had developed a knock. The only thing electronically that I changed was the points because they looked better than the ones I had. I guess I can swap those tomorrow also. Anything anyone else can think of? I'm pretty much stumped here. Please don't tell me to clean the carbs again, because they are clean... every hole, orifice, and port.

Tod

[Kevin W]

Tod,
I'm sure you've got the answer already, but just in case you haven't
I wondered about the circlip on the end of the shaft as you did on the middle drive end, and it is as TC said. It's a BIG c clip holding that bearing in.
By the way, I put the washers you sent me on both sides of first gear. That leaves the middle drive right where it's supposed to be. Probably not that big of a deal.
Wish I could help with the other, but I have NO experience on that end.
KW

[trbig]

I hope it works out great for you. My bike SHIFTS fine... I just can't get it to run worth a crap... anyone have any ideas?

Tod

[Stralya]

Plugs

I know this sounds insane but I recently went through similar pain. Try changing the spark plugs, it worked for me

Dan

[oldnortonrider]

Some time back (I've had this happen on two different occasions) I had the cam chain "slip" a link on the crankshaft sprocket, when messing with the cam chain tensioner. It would act/run like what you're describing.......(??????)

[mro]

The only thing electronically that I changed was the points because they looked better than the ones I had.

I've got a few XSes but no XJ.
So they have "POINTS"


mro

[John]

He was refering to the pick up coils.
Tod, you may want to look at O rings on the float seats. With#1 being as loose as it was, and the O ring as flat as it was, you may be having a rich condition.

[planedick]

Washer idea...

I thought about the washer thing when I did my tranny fix, but I found that it made no difference because the position of the gear on the shaft is held with the shifting fork. Also, Harbor Freight has a real nice set of diamond bits (and they are cheap) for your dremmel that really work great for shaping the recess and dogs on the first gear fix.

[trbig]

I found that it made no difference because the position of the gear on the shaft is held with the shifting fork.

That's why you move the washers to where it shims the gears closer to the ones with the shift forks on them. 3rd, 4th, and 5th have the shift forks on them with dogs on those gears. You are shimming 2nd and in this case 1st closer to those. It does make a difference. I tried the diamond bits that are actually a chainsaw bit, but the carbide tip was the best at taking a lot of material off, and the red stone for finishing.. #932. It's the one that you actually have to lightly force through the slots, but it gives a good repeatable smooth rounded slot that I just couldn't get with the thinner bits. And the one little stone finished every slot and dog in my tranny and still looks good. Just my 2 cents worth.

And... I put brand new plugs in it at John's... forgot to add that. No change from the old ones to the new. I will try new O-rings though. Just kind of strange how the carbs were working fine in one motor... I'm still wondering about the pickup coils... sorry I called them points.

Tod