Question about washer move on tranny

[DGXSER]

The washer swap is completely optional Silent. I did it on mine, seams to be working great. Highly recommend the TechTip of you don't already have it printed out.

These guys did an awesome job documenting the process in my opinion. If you do a quick search there are several threads on this fix just since I came on board (so to speak). Lots fo great info here and plenty of great help!!

[DiverRay]

DGXSER asked:

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?

Yes, there IS a tool for it. It looks like a pair of needle nose pliers, with the flat on the OUTSIDE of the jaws. There are two or three sizes, depending on the size of the clip. The small one should work well.

[Silent]

The washer swap is completely optional Silent. I did it on mine, seams to be working great. Highly recommend the TechTip of you don't already have it printed out.

I've read alot of info on this board about it already. I've got the dog undercutting article printed, and plan on doing both 1st, 2nd and the washer move

[joebus]

So i got everything apart. I need to put a order in for all new gaskets and the c-clip i bent in half and the spring clip i bent enough for the second gear not to spin when i got it back on No worries, i will have it all together this next weekend and all the parts are cheap.

[DGXSER]

Many have bent that clip that holds 2nd on and just use a vice with cloth wrapped around the clip (in my case) or a hammer on a flat surface to flatten it back out. It usually does get twisted a bit getting it off, at least in my experience.

[trbig]

4-5 bucks for a new one.. If you bend it up that bad, replace it. A lot is riding on that clip.

Although.. I'm finally glad to meet someone cheaper than me!

[XSPastor]

So i got everything apart. I need to put a order in for all new gaskets and the c-clip i bent in half and the spring clip i bent enough for the second gear not to spin when i got it back on No worries, i will have it all together this next weekend and all the parts are cheap.

It might not be a bent c-clip that is causing 2nd to not spin freely on the shaft. I had to grind the inside edge of the washer where it sits against the countershaft shoulder because the inside corner of the shaft shoulder is rounded. The washer won't sit flat against the shoulder of the countershaft unless you do this. Yours might spin freely without grinding the washer but mine certainly wouldn't. Check this if it still binds with the new c-clip.

[joebus]

I grind down the washer a little but maybe not enough. that c clip had to go because sometimes I muscle things instead of using my brain
I am learning a lot about the bike doing all of this which is awesome.

[XSPastor]

The Best Part!

I grind down the washer a little but maybe not enough. that c clip had to go because sometimes I muscle things instead of using my brain
I am learning a lot about the bike doing all of this which is awesome.

That's the best thing about it, Joebus. You'll know all about your bike when you're done and there will be a little less mystery to fixing it. That, and the satisfaction of a job well-done!

[joebus]

anyone know where i can get the locking washer for the big clutch bolt? Not having much luck...

[XSPastor]

Clutch Lock Washer

90215-19139-00 WASHER, LOCK $2.83

Buy it here.

[GNEPIG]

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

Wow Tod, Great pictures and discription in this other thread. Thumbs up!

When replacing the spring clip, make sure that you put the smooth side against the gear (the sharp edge away from the gear), this will also help it to not bind.

[joebus]

I got the spring clip back on and have all of the gears put back together. Putting them back in is a whole different beast. I have put about 3 hour long tries to get it back in with no luck. I will just keep plugging away at it. Its 35 outside today and it does not look like it will be getting much better so no worries on time.

[DGXSER]

Hey Joe,

Yeah, that was probably the hardest part of the entire project for me also. With the exception of scraping the gasket off of the fork cover engine side surface. IT is one of those "you gotta hold your mouth right" while your doin it things, other words, get lucky and it slides in.

Here is a link to a thread from when I did mine. A couple pointers on how I got it to go.

http://www.xs11.com/forum/showthread.php?t=20461&page=3

I actually travel through Indianapolis quite frequently, we have an office in Fishers.

[joebus]

I read the thread and i will give it another shot. Also when I took out all of the gears the forks kinda fell out and I am having a hard time with what order they go on ... Thanks for all the help thus far!