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**DiverRay** · 02-04-2008, 12:56 PM

I replaced two wheels with new, and did the grind on the rest. I have about 50K miles on it, and it still works well. I just used the eyeball, MKI to do the slots and dogs. The big thing is to try and get all the dogs to hit the slots at the same time.

**motoman** · 02-04-2008, 05:03 PM

tranny fix?

Its just kind of a PITA..........easy to do, just takes a little time. Just finished doing mine yesterday. A little angle doing dogs and angle slots to fit. Had set bike higher off floor on center stand on two short 6"X 6"s. Easier going back together..........results in applying a more firmer shift since edges of slots and dogs were left square-edged. Got to test for some 15miles and the pay-off is same as when bike was new. The NOS left-side complete exhaust helps the smiles a bit too...............Sounds like the day I rode it off the showroom floor new

.

**AlanB** · 02-04-2008, 06:53 PM

Hi Marty,

It is a little more accurate than just an eyeball...... As you grind, you just keep trying the two cogs back together.....

It is pretty easy to tell when all the dogs meet all the slots at the same time........ If they don't...... keep grinding until they do.

Hand fitted; better than factory. LOL!

There is a related mod which moves a washer along the shaft. Some bikes respond to this mod alone. Other bikes also need attention to the selectors....

Many, many members of the forum have done this repair; I don't remember hearing about ANY cogs breaking up......

Even if it did go wrong, new cogs will still fix it. It only cost a couple of gaskets and some time.

AlanB

**trbig** · 02-04-2008, 08:18 PM

The last one I did, I used a micrometer to measure and get all the dogs the same width, then I measured the slots where I ground them to the slot underneath it that didn't get touched, and got all these slots to the same thickness that way. Make sure to move that washer for 2nd gear to get the dogs closer. You are the first person I have heard of breaking off one of the dogs??

I don't know anyone that rides them harder than I do, and I'm no lightweight at 250+. I haven't had any problems even doing wheelies and such. You really don't take off much "Meat" in this process, just getting that little bit of rounded edge off and cutting it back just a touch. You can see in this photo that just about the thickness of this washer is all of the dog that is getting engaged in the slot. Moving that washer basically doubles the amount that gets engaged. This dog pictured is almost done being cut. You can see that there's not much gone really.

Tod

**jetmechmarty** · 02-04-2008, 10:32 PM

For the record, the dog I broke was on my XS650. It's very similar in design although it doesn't suffer the transmission woes of the XS1100.

**trbig** · 02-05-2008, 07:05 PM

Marty had asked me some questions about moving the washer/spacer for the 2nd gear, so I thought I'd post some pics here explaining it. In the tech tips, TC also goes through this process, so just throwing in a few extra pics to help.

In this first pic, the motor is upside down and the rear at the bottom of the screen. Marked in order are:

A. This is the gear that drives the middle drive

B. 1st gear solid but with raised ribs to accept 4th gear dogs

C. 4th gear with dogs

D. 3rd gear

E. 2nd gear with slots

F. 5th gear with dogs

In the next pic, the gears are on the counter situated in the same way.

The next pic shows the 5th gear dogs slid back to show the slots in 2nd. You can also see the solid 1st gear I mentioned second from left in the pic.

5th gear and dogs removed from the shaft

On the shaft, there is a slot that a spring retaining clip fits in. So looking at it in order, there is the clip, a washer/spacer, and then the 2nd gear.

Here is a closer look. A. is the spring clip. B. is the washer/spacer.

So.... what you need to do is remove the spring clip, and the washer and gear can be removed from the shaft. Upon re-assembly, you'd put the washer on first, then the 2nd gear, then the spring clip goes back on. This will move 2nd gear just a touch closer to the dogs on 5th gear under operation. This has been shown to greatly help avoid future slipping problems.

This may be a bit mundane for some, but hope it helps someone.

Tod

**Gyrogearloose** · 02-05-2008, 08:56 PM

Tod. These pics help alot! I'm thinking of doing this same mod and the more I see, the better I feel about starting this project. Thanks.

**stoked** · 02-05-2008, 10:58 PM

Todd, those pics are about as good as having the parts right in front of you. They should be added to the Tech Tips with the previous washer move article. It also makes me wonder why not having the washer there between the gear and the clip really matters. I mean what's to keep the washer from spinning anyway? And there is now way the actual force on the cir clip will be any different without the washer there. The actual force on it will be exactly the same. I'm going to do this and what I will probably do is chamfer the cir clip like you do rings before installing them on the pistons. Except chamfer the side that faces the gear of course. That is the only minute concern I can see. That if some way the motion of the gear could snag the clip and lift it enough to start it coming out of the recess.

I've put about 8k miles on the bike since I've gotten and only had it come out of gear one time. But that was second gear so I'm going to do this washer thing now to see if I can keep this from happening again. What's funny is my Kawi comes out of gear in several gears on occasion and I pay no attention to it. But the second gear XS issue is so pervasive it makes me want to act on it. If I had never seen this site I'd probably had never concerned myself with it and eventually thought all hope was lost once it started slipping out all the time.

**DeanR** · 02-06-2008, 05:28 PM

These pics definitely need to be added to the tech tips. Thanks Tod..

**John** · 02-06-2008, 05:44 PM

Don't tell him that...it'll go to his head.

**81xsproject** · 02-06-2008, 09:23 PM

Having cruised through the tech tips, I have to agree that Tod did a great job. I too now feel more confident about doing the repair. However, at 25k, mine has never slipped.

**trbig** · 02-06-2008, 09:46 PM

LOL..

I'm glad you guys liked the pics, but this doesn't really explain the mod... just explaining where the washer is and needs to go. This says nothing bout the grinding of the dogs/ slots which should go hand in hand with the washer replacement since you have the gears out, or the disassembly/reassembly of things. Simply moving this washer isn't in itself going to fix anything if your tranny is skipping already. And if it's not, this simple washer swap wouldn't be reason enough to tear it down.

Tod

**mro** · 02-07-2008, 12:56 AM

chamfer the cir clip

Should make no difference. All spin same.

Pisses me off that when I've had engines apart that I didn't do this. Cheep insurance

. None had any tranny issues and as far as I know all are still good...but...

mro
btw, very good pics Tod

**Ken Talbot** · 02-07-2008, 01:49 AM

Reflections.....

These photos are great, Tod.

I feel a great satisfaction when explore my hard drive, and see the 1998 date stamp on the first files I put together to document the "Black and Decker" fix. Then I see the continuing efforts of other XSives over the years to better explain and illustrate the various procedures involved. Of course, TC, - this includes your significant efforts to refine all this stuff. Tod, this latest batch of photos are way beyond what I could produce "back in the day" with my 1.3 megapixel Fuji that cost me $1600!

Every time I see somebody post a link saying they are embarking on this fix, or reporting that they have successfully done the fix, I get a nice warm glow inside. And let me tell you, folks, there have been a lot of people do this fix since 1998! That glow has kept me warm through a lot of otherwise cool times.

IMHO, this is what makes the XS community what it is. People come up with an idea, then other folks join in to refine the idea, so others who come along later can take advantage of all the trials and tribulations that came before.

We have had our rough spots over the years, here at channel 11, but I wouldn't trade any of them for the world. Sid - you with me on this?

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Replace gears vs. grind dogs/slots

Replace gears vs. grind dogs/slots

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