2nd Gear Fix ideas

[bikerphil]

shift forks

When I repair these trannys, I just do 'em on the centerstand, right side up. With the bike upside down, be careful not to drop the shift forks down into the engine, as they might be difficult to retreive (non-magnetic). This isn't a problem when repairing right-side up. The forks just tend to fall on your face, along with the oil. Good luck!

[Pat Kelly]

I did mine with the bike upright, on the centerstand.

[trbig]

I did mine with the bike upright, on the centerstand.

Me too!! Except the engine is always out of it and split in half when I do mine! lol.

Tod

[madmax-im]

Both times when I had to go into the tranny I flipped the bike... mine was the Maxim XJ1100 it has the stronger handlebars so blocks of wood ...etc...were not necessary...one thing you want to do is pay attention to the exact order and orientation of each gear...regardless of which way you prop the bike up.I might add if there are any XSives in your area perhaps they could be recruited to come and give you a hand.I was fortunate to have Randy on the first attempt and then TC on the 2nd and final attempt.I bow ..tip my hat to them.For their help was priceless

[DGXSER]

Gears are out!!

Well, I went with the centerstand method. I got the countershaft out. All the forks look good, expected wear at the gear contact patch only.

Did find that someone has been in there before, one of the ears to the countershaft bearing cover, with the torq bolts, has been snapped off. No sign of it anywhere, did find a minor amount of metal flakes in the oil pan and on the screen of the oil pump. Minor equal 3-4 no more than 1/8" long and barely noticable thickness.

1st/4th gears look almost brand new. 2nd gear slots and 5th gear dogs are not much if any worse than the ones shown on the "Second Gear Repair Illustration" thread. I will try to post some pics.

All together I would say it took 4-5 hours of work to get the countershaft out, but I certainly moved slowly and deliberately.

Next step, the dremel work. That will wait until tomorrow, or later. Need to make sure I take my time on that part. Any oen tried it with the flex shaft? Any easier, harder that way?

Thanks again to all for the support and encouragement!!

[DGXSER]

See if this link works. To my photobucket site with my pics form this excursion. I did find it interesting I can see where 5th dogs rub across the face of second when it skips. Makes me a bit sceptical of switching the washer though. On the other hand I wonder if just the washer is all it needs. Maybe I am just feeling lazy about it now. Is this typical?

Also, when you dremel the gears is eyeball fit close enough for making sure they are the same, engage at the same time?

http://s443.photobucket.com/albums/qq160/dgxser/XS11%20Tranny/?start=20

[bikerphil]

To post a pic. with photobucket, go below the pic. you want to post and click on IMG link. It will say copied. Then paste it in your post.

[bikerphil]

Resurface the gears, make sure they all contact evenly by eye. Check 1st/4th combination for wear while you have it apart. It's well worth the extra time to make sure all the gears are cleaned up good while you're in there. Trust me, moving the washer greatly extends the service life of the 2nd/5th combo. A tip that might not have been mentioned... When reassembling the gears on the countershaft make sure the retaining clip that sits to the left of 2nd gear is perfectly flat. You probably noticed it was difficult to remove and wrestling it off the shaft might distort it. If it is slightly bent, it will add drag to 2nd gear instead of it freespooling. This will cause a poor syncronization when shifting from 1st to 2nd. DAMHIK.

[XSPastor]

Resurface the gears, make sure they all contact evenly by eye. Check 1st/4th combination for wear while you have it apart. It's well worth the extra time to make sure all the gears are cleaned up good while you're in there. Trust me, moving the washer greatly extends the service life of the 2nd/5th combo. A tip that might not have been mentioned... When reassembling the gears on the countershaft make sure the retaining clip that sits to the left of 2nd gear is perfectly flat. You probably noticed it was difficult to remove and wrestling it off the shaft might distort it. If it is slightly bent, it will add drag to 2nd gear instead of it freespooling. This will cause a poor syncronization when shifting from 1st to 2nd. DAMHIK.

My second gear wheel did not spin freely on the shaft until I chamfered the inside edge of the washer where it rides against the counter shaft shoulder.

[bikerphil]

My second gear wheel did not spin freely on the shaft until I chamfered the inside edge of the washer where it rides against the counter shaft shoulder.

Yep, whatever it takes to get it to spin freely. Having a notchy shift from 1st to 2nd really su*ks. I hammered the clip on the vise anvil, straightened it with pliars, and filed it down to take off the rough spots. Just missing that little detail will cause you to blow shifts from 1st to 2nd, especially at higher rpm's.

[DGXSER]

Thanks

Thanks for the tips. I have not got that clip off yet. I have the tool for the circlips. For that one I have always used screwdrivers against each other in the past for that kind. Do they make a tool for it? I will make sure it goes back in flat. It would totally suck to go through all this and get it back together only to find that problem.

As to the photos, I put the link in to photobucket just do the number that are there instead of posting them here. Let me know if it does not work. I tried it and it worked for me when I was logged out of photobucket.

I will definitely dremel fifth and second and eye them up REALLY good for fit. Maybe use the old lipstick trick like you do for deadbolts. first and fourth I am debating on. It has not slipped for me yet and certainly looks to be in perfect shape. But then I do NOT want to go through this again in a year or two.

Thinking ahead to the reinstall, with the clutch, what is the issue with the star plate. It does not seem to realy line up with anything, springs etc..what am I missing?

[bikerphil]

Tried copying the photobucket link, didn't work. Here's the link for the star plate warning...

http://xs11.com/xs11-info/tech-tips/...y-warning.html

I take that clip off with two small screwdrivers and work your way around until it's out of it's groove.

[DGXSER]

ok, here are the pics of the gears and the countershaft bearing.

5th gear dogs


Top view of 5th dogs


2nd slots


1st slots


4th dogs


Countershaft bearing

not sure I will do anything about it but just button it up like it was.

Sorry that some are not as clear as I would like.

Have over 30 pics total as I took a pic before and after removing each part of each case so I knew how things went back, and also took several of the tranny before removing anything to make sure I knew how things go back and how the forks were positioned etc. I know better than to go from memory, experience is a great teacher.

[trbig]

My local True Value hardware store had some stainless screws the size and length I needed to replace those Torx heads to Phillips heads.

On the issue of the 2nd gear being a bit stiff after moving the washer... I just installed them as is. Running the bike will loosen everything back up.. or always has in the several cases I have seen. I've never heard of shifting problems like Bikerphil mentioned before now.


Tod

[DGXSER]

ok I did the back cutting on all four gears, second and 5th dont look the prettiest, but should work.

Now, what is the secret to getting the middle driven gear and first to fit back up in there? I see how the middle gear fits into the bearing area in the tranny side, and first must clear the larger gear on the main shaft. Only way I get them to clear is by sliding first off its bearing, but then I cant get the bearing back on to get the countershaft to slide into the bearing.

Any advice would be very appreciated.