Question about washer move on tranny

[joebus]

So I am going to tackle the transmission this weekend. I have a question about the task that the search did not help me find. I was planing on doing the washer move while i have the gears out but I cannot find a pic of which washer I move and where I move it to. Thanks for the help

[DGXSER]

2nd gear

Joe,

The washer in question will be between the "C" clip that holds 2nd gear on the countershaft and 2nd gear itself which sits against a shoulder on the countershaft. It is a pretty thin washer, much thinner than the clip itself IIRC. Got to this site, look up the microfiche of the transmission and it is part no 21. it moves to the other side of 20 which is 2nd gear.

http://www.yamaha-motor.com/sport/parts/home.aspx

You will most likely remove 2nd gear from the countershaft in order to back cut it. When you get ready to remount the gear, just slide the washer onto the countershaft prior to 2nd gear, moving it to the other side of the gear, then remount the gear and re-install the clip. This will move 2nd gear that much closer to 5th, increasing the amount of engagement between the dogs on 5th and the slots on 2nd gear.

I have about 200 miles on mine since the repair was made in December and could not be happier. I hit it pretty hard on occasions just for the sake of testing this repair and it has never slipped a bit.

[FJ111200]

This is what i used. Top site this. http://www.xs11.com/forum/showthread.php?t=154
Nearly as good as www.benefiscal.co.uk/forum

And mine has held up good, but i replaced everything with new/near new from left to right/right to left, if you get my drift.

[trbig]

To see what washer they are talking about, I took a few pics here. Go down to the 7th post. Maybe a little closer pics you can see what they are talking about.


http://www.xs11.com/forum/showthread.php?t=16390

Tod

[joebus]

Awesome! thanks for the help. I have to get this done this week because my wife is due to have our first child in a week and time will become limited.

[DiverRay]

Don't forget, you WILL need to "trim" the INSIDE of the washer. There is a taper on the shaft at the rear of 2nd gear. the washer need to clear that. I found a rat tail file, or a few seconds with the dremel, will do the trick.

[joebus]

Anyone know what size the clutch nut is????

[joebus]

27mm just so everyone knows...So i got the 5th gear out and i cannot get the rest of the gears out period. All the shift forks are out but it just will not come out no matter how i twist or move it. anyone got any tips?

[bikerphil]

Did you take the 14mm bolt out of the countershaft?

[joebus]

Yeah I had it out. I think I just needed to walk away from it for a min because it all came out when i tried it again. Now I am just grinding away at the gears!

[joebus]

So is there some magic way of removing that spring clip holding 2nd gear in?

[DGXSER]

Screwdrivers, and almost as much patience as it will take to put the gears back in the bike.

I used two screw drivers to pry the ends away from each other and get one up out of the groove, then use one to hold that end up out of the groove and the other to wedge between the clip and the shaft between the raised parts of the shaft to pry it out and up the rest of the way around.

[DiverRay]

They also make a tool for removing them! Should be about $15 to $20 in most auto parts stores. The tool makes it REALLY easy.

[DGXSER]

Ray,
The C-clip tool works awesom on the ones with "eyes" on the ends of the clips, not sure how it would work on the second gear one with flat ends and very thick material. Is there another tool I am not aware of for those?

[Silent]

Very timely material. I'm in the process of tearing down my '79 Special for exactly the same fix.