5th Gear Blues Questions

[Ryan Stanley]

I just purchased a 1981 Yamaha XS1100H a week ago, knowing that there were a few problems with it. Probably the most significant issue is the fact that it will not shift to 5th gear. I read the "5th Gear Blues" post, and it was helpful, but I am an absolute novice when it comes to transmissions, and I want to be sure I know what I'm doing when I tear into this project.

Question #1: I assume there is some kind of "o-ring" or seal involved behind the shifter plate. Is this something I will need to replace once I open it up?

Question #2: The "5th Gear Blues" post says that when you're done, to fill it back up with oil. Call me stupid, but what kind of oil and where does it go?

Basically, I want to know what all I will need to put the thing back together once I open it up, so that my bike doesn't end up being out of commission for any period of time.

Can anyone help me out here?

Thanks.

[ClarkGriswald]

The shifter and clutch covers simply have gaskets behind them. Reglar rubber/fiber ones.. you can buy them or I think buy the whole engine gasket kit for cheaper.. I just did my gears too and I think those gaskets were like 15 or 18 bucks a piece so I made my own (if your good at fiddlin with that stuff) for 5 bucks for the material.

I belive the oil is around 3.2 quarts or so. Im just running 20/50 yamalube (regular dinosaur oil) and it goes in the top of the clutch cover on the right side (little knob looking plug).

[Ryan Stanley]

Ok, I think I see the plug you're talking about. So, just to clarify, I have to take off the plate that the shifter pedal connects to, correct? The cover to the right of that would be the clutch cover? Do I take that off too?

Sorry for the stupid q's, just making sure I understand it all.

[TopCatGr58]

Hey there Ryan,

Congrats on your new acquisition, and finding this site!!

Okay, first you can get a copy of the 81H/SH Owner's Manual in PDF by following this link to a thread in the LINKS section, and D/L'ing the file from the included link, will show you basic info about oil and filter changes, fluid levels etc!!

Next, follow this link to find how to access online SERVICE MANUALS.

Also, you can view exploded views of systems of our bikes by following this link to Yamaha's Online Parts Fiche site , just go straight to parts list button, then select Motorcycles, year, model, and then the system you want to view!

The shifter cover uses a shifter shaft seal, but it doesn't need to be replaced, will slide off the shift lever when you pull it off, and then slide back on/over when you put it back on, just suggest putting a small film/layer of oil on the inside edge of the seal when you put it back on. The cover IS an oil chamber, and requires a gasket when you put it back on, you can get plain gasket material in a roll at your auto store for a few bucks, and cut your own, using a single hole punch for the bolt holes! I prefer to use gasket sealer, others go back dry, but being an oil chamber I don't like the chance of leaking, and also don't usually plan on going back in there anytime soon after I've done the repair!

IIRC, I had to loosen the foot rest bolt to allow easier access to some of the case bolts, and for easier removal and reinstallation.

As you hopefully have found with your review of the other posts, you'll want to get a new plate that holds/secures the pins in place, cause once it bends, it's never as strong and just bending it flat won't hold!

And need to be sure to keep the alignment dots on the shift pawl/gears correct when you put it back on, holding it in place as you slide it back over the shift shaft, IF you pull it back away from the engine, it will pull the shift shaft and gears apart and they will slip out of line, and you will end up with ONLY 1st gear and neutral!

While you're in there, might as well order the $10.00 shifter return spring and replace it, tends to loose it's spring and can cause problems with downshifting when it gets weak!!

Good luck, and remember, we're here if you need anything else!
T.C.

[Ryan Stanley]

Thanks so much for the help. Wish me luck!

[Ryan Stanley]

Okay, so I fanally got around to opening up the shift mechanism today. Yes, that little plate has a bent tooth on it. And the pin behind it is nowhere to be found. So I guess I have to order them both.

Also, someone mentioned that I should replace the spring. Is it the big spring behind the shift pedal or the little spring at the top left?