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**uk1.1s** · 03-20-2003, 11:30 AM

XS 11 gearbox...the horror...

Herbie,

Welcome to the horror of the XS11 gearbox!

If the clunk/crunch from neutral into first is terrible - then everything is running as designed!

Seriously, it makes a LOT of noise shifting into first from neutral, this is for good technical reasons, the bad design. There are Technical Tips relating to the gearbox operation somewhere on the site. I think most peoples conclusions are:

1. Don't shift into first when not rolling if you can help it.

2. Shifting into first from neutral when you're not moving takes some technique. Pull the clutch in early and wait for 10-20 seconds before shifting.

The reason for No. 2 is something to do with the gears in the transmission spinning relatively quickly, even in neutral at idle speed. Most bikes have a better design where the gears spin slower or not at all I suppose.

There sometimes is a bit of a forward lurch in changing to first, which can be put down to 'normal practice' too.

However, to check for a dragging clutch, try putting the bike on the centre stand with the back wheel off the floor. If by shifting into first (and keeping drive disengaged with the clutch) the rear wheel keeps moving then you have a dragging clutch. If the wheel moves some in the initial gear change (causing your lurch or 'creep forward') and then stops, then that's probably the vagaries of the transmission rather than the clutch misbehaving.

I used to get stares of amazement on bike club run-outs when I changed into first at traffic lights by all the other club members sat around me. Now they are just amazed that the gearbox doesn’t need rebuilding every 1000 miles.

**skids** · 03-20-2003, 11:48 AM

The cable adjustment is just for cable free play. Make sure you maintain a little free play for the following:

The clutch adjustment is under the right side cover that is held on with two screws. Loosen the buddy nut, turn the adjuster screw counter clockwise, then clockwise until you feel a slight resistance. Then back the adjuster screw off about an eighth turn. Tighten the buddynut. Check the cable free play. Reassemble and go.

If your bike sat around for a long time, there may be some corrosion/roughness on the pressure plates. This will wear off eventually. You might want to lower your idling rpms to about 1000 to help your transmission until the drag disappears if it is due to the reason described here. Hell, go try some "clutch" wheelies to rub-off the roughness!

**Robert Haller** · 03-20-2003, 02:02 PM

Re: XS 11 gearbox...the horror...

Originally posted by uk1.1s

1. Don't shift into first when not rolling if you can help it.

I used to get stares of amazement on bike club run-outs when I changed into first at traffic lights by all the other club members sat around me. Now they are just amazed that the gearbox doesn’t need rebuilding every 1000 miles.

When I shift from neutral to first at a stop, it sounds and feels like I'm beating the gears with a hammer to engage. So I leave the gearbox in first and keep the clutch in (though this can make for a tired left hand). Are you saying that pulling the clutch in 10-20 seconds before engaging first avoids that horrible clunk?

**Red Baron** · 03-20-2003, 10:50 PM

It will still clunk, but not lurch. This is common and these are really tough transmissions. Be sure your clutch cable is free and lubed. Play is necessary in the clutch lever, about 1/8" from lever to housing, this is to completely engage the clutch.

**Dennyz** · 03-21-2003, 10:32 AM

The clutch problem you are experiencing is common to the XS. Out of the 7 XS is my family, 4 of them have had it.

After much research, we believe it is do to the wear of the pressure plate. To verify this, check the clutch fibers thickness. My bet is you will find them "in Spec".

What seems to be happening is, over time the clutch system has more travel than the springs can accommodate. The end result is either partial engagement at idle or slipping at the high end. When we disassembled the clutch basket, we found the pressure plate had .040 to .060 of wear.

We found several options:

- Shim the clutch springs. It does not take much. Most of the time a .040 washer does the trick.

- Replace the springs with longer ones. Some aftermarket springs are slightly longer.

- Disassemble the clutch and replace the pressure plate. It is the one locked into the clutch basket and still available from the dealer (as of 2001).

My family has applied all three of the solution with positive results. The first option is the easiest, the second requires the help of a distributor, and the third is actually fixing the problem.

Note: A worn out cable can cause the same symptoms. It usually does this just before it fails. If the cable is going, it typically happens over a short period of time.

**skids** · 03-21-2003, 06:27 PM

Be careful about the washer trick. I tried it and broke the star plate. I did it wrong--don't do what I did! Do not slide the springs over the posts and then add the washers and then the star plate. If you do, the washers end-up deforming to half-moon shapes and act as "wedges" that break off the tips of the star plates as you install the bolts.

Originally posted by Dennyz

We found several options:

- Shim the clutch springs. It does not take much. Most of the time a .040 washer does the trick.

**schpiff** · 03-22-2003, 03:52 AM

clunk

I too am concernd about the shift (noise)..I have been assured by these guys ans gals that the XS is a "clanky" shifter..I myself have an 81 with about 10 k on it and it sounds like something is really slack on every shift...But...if it works.......go

**TopCatGr58** · 03-22-2003, 09:58 AM

Clunky Trans

Hey there Schpiff,

I did the 1st, 2nd gear fix on my '81 a couple years ago, it's holding just fine, I have plenty of oil in trans/middle gear box. I was out riding with some V-twin friends, one riding behind me, and he told me after one stop that he was sure he was going to see tranny parts dropping out behind my bike because he could hear it SHifting/CLUNKING as we rode and ran thru the gears!!!

And I use the clutch when I shift!!! Welcome to XS11's !

**schpiff** · 03-22-2003, 11:59 AM

Yep

I had the same thing told to me..! My brother has a vstar and we were out yesterday..he said almost the same thing...heheh..I was thinkin it sounded loud..but when another guy in the wind can hear it ..its gotta be loud..From the info I have got its just (one of those things..) Now that I have mine runnin close to pretty good..I can put up with the clank...cuz other than that..What a SWEET ride....thinkin I'm gettin xsive...lol

**TopCatGr58** · 03-23-2003, 08:44 AM

Gettin' Xsive

Hey there again Schpiff,

Due to my having performed that dreaded Dremmel 1st and 2nd gear fix, I now try to avoid too many shifts into 1st from a dead stop, I hold the Clutch Lever at stops and make sure I'm in 1st well before coming to a stop. The constant beating of 1st gear from Neutral into 1st is what wears down the "Dogs and Slots" and leads to the popping out of gear syndrome that can develop. SO...hopefully this technique will allow my 1st and Second gears to endure quite a few more years yet!!! Enjoy and have some great rides.
T.C.

**skids** · 03-23-2003, 11:59 AM

Re: Yep

I like the sound of the transmission when it makes a resounding "shunk." I know it has complete engagement. I have another model E that is somewhat more finiky, which also has more "false neutrals" and tends to "click" into gear.

Originally posted by schpiff
I had the same thing told to me..! My brother has a vstar and we were out yesterday..he said almost the same thing...heheh..I was thinkin it sounded loud..but when another guy in the wind can hear it ..its gotta be loud..From the info I have got its just (one of those things..) Now that I have mine runnin close to pretty good..I can put up with the clank...cuz other than that..What a SWEET ride....thinkin I'm gettin xsive...lol

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