Transmission Gurus

[subike]

At the moment I am doing a rebuild on my 79std.
Having stripped the complete bike to repaint the frame, add some bling and do a few mild custom changes. the engine unit is on the table in a very accesable position to do the 1st & 5th gear dog mods.
So I have the engine upside down and have removed the pan, oil pump bla bla bla.
On inspection of the gears that need the Dremel fix, I have fond that they are new!
Surmising that, when the engine had its rebuild by the PO, he had the gearbox done at the same time, fitting new gears, this also may have been the reason the motor was rebuilt. Shrapnel in the bottom end. Ugg!
So my learned XS owners, gearbox gurus, advice please, before I reassemble the box.
Do I do the Dremel fix to these gears before reassembly, even though they are new? Or do I reassemble and ride her accordingly knowing this is a weak point. I have the dremel and stones to do the job,
I understand that if I dont, I may in the future have to do it anyway, but I would like opinions on this, or any other advice.

PS. look forward to a NZ custom XS appearing in the forum by Xmass.

[Crazcnuk]

Look at the new dogs, if they are backcut, slightly, then you don't have to do them.

The factory updated the replacement parts so thqat they don't need the dremel fix.

[TopCatGr58]

If you'll look in the Member's Lounge at the SURRENDER thread by BNE, you'll see some photos of NEW gears dogs, showing the SLIGHT backcut of the gears. Hopefully you can see and compare to help determine if yours are backcut.
T.C.

[subike]

Thanks for that lnfo TC,
I was able to see that I have the "new improved" gears from Yamaha. Choice, then no dremel work needed.
But upon reading the "No Surrender" thread, and then looking at the "Dremel fix" thread pic, I noticed something.
No kick start gears!
Mine being a 79E it has the kick start gears,
mmmm, So, even though I managed to remove the gear cluster with the kick start gears in place, albeit a jiggling juggel cuss cuss job, would removal of the kick start gears make reassembly of the gearbox easier?

[subike]

Ok got my tranny back togeather today, with a little jigling, a few choice words and no skinned knuckels.
Have checked out all the movements, running from first to fifth and nothing is bindging, all changes were smooth all the gears moved the right way, good.
I asked a question in the previous post re the Kick start gears.
I have left them out of the box. I removev the shaft and gears from their housing and bolted the empty housing back in place.
I will still hace the external shaft protruding from the clutch cover when reassembled, but it is unoperative inside the trans.
Should I expect any problems with this?
Oh, I tied a cotton thread to each of the control forks to pull them back up out of the engine, bit easier than long nose pliers.

[trbig]

That's how I have mine also. I had cleaned up the sidecover of the 78 motor I had in it originally when I bought it... so I had to keep the shaft coming out. Just make sure you hook the spring on this shaft to the proper spot under the clutch cover so it isn't rattling around and getting into the clutch basket or anything.






Tod

[madmax-im]

Glad you got your answers..I was gonna chime in that if you already have new factory backcut gears then you are good to go.....this is what I decided to do...rather than dremeling the old gears...I just replaced them all with the new factory backcut gears...saved a few hours work in the process...plus I am secure in the knowledge that the weakest link in this bike is no longer..peace of mind...priceless..Best of luck on your rebuild..refurbishing

[subike]

Thanks for the heads up on the information guys.
Tibig, I am going to remove the kick start shaft as well, the "hole" in the clutch cover I am going to fill with an automotive welch plug, from the inside out, using shelack as a sealent. As I am painting the cover black, this will not look out of place. Why keep something on the bike that will never have any practical use. Also its a bit more weight that is not needed.

[Crazcnuk]

There is a factory plug you can put in there, from the 80 models.

They had the hole, but no gears, and so came with a plug.

[subike]

Yeap there is indeed a factory plug.
From a yamaha dealers it would cost me NZ $5
The welsh plug is $0.50.
Does the same job.

[Crazcnuk]

Same job, but looks like 0.50, and eventually the rat bike is covered in them...

[Geezer]

Since you have it apart, polish the face of the gear dogs and you won't believe how well it shifts after that...

Geezer