2nd gear fix parts list

[Jerry]

For those who are contemplating the "2nd gear fix" for your XS or XJ, here is a quick parts reference list.

Part numbers for the 3 needed gaskets are:

2H7-15451-00-00 Gasket, Crankcase cover (Clutch side cover)
2H7-15461-00-00 Gasket, Crankcase cover 2 (shift shaft cover)
2H7-13414-00-00 Gasket, Strainer cover (oil pan)

Exhaust gaskets (4 needed) are:

431-14613-00-00 Gasket, exhaust pipe

Part numbers for the gears are:

2H7-17221-01-00 Gear, 2nd wheel (39T)
2H7-17251-00-00 Gear, 5th wheel (30T)

2nd gear washer part number is 90201-30398-00, but is no longer available from Yamaha.

In rare cases you may need shift forks:

2H7-18511-00-00 Shift fork 1
2H7-18512-00-00 Shift fork 2
2H7-18513-00-00 Shift fork 3

Forks are numbered left to right as you are sitting on the bike, so fork 3 is closest to the clutch.

While this list doesn't cover all the parts that might be needed in all cases, these are the most commonly needed parts.

You should read all the related articles on Ken Talbot's web page at:

http://www.rctvonline.net/xs11/

2nd gear...the saga continues....

[beechfront]

just did mine last night. don't have all the covers on but got the gears all back together. My 2nd and 5th gears looked really good. The only thing showing any amount of wear was the first gear wheel (2h7-17211-00-00). All I did was move the spacer to the other side of 2nd.


One thing that helped me out alot was one of those magnetic wands. i had my engine upside down and trying to get those forks in was a real bugger.

[TopCatGr58]

Originally posted by beechfront
just did mine last night. don't have all the covers on but got the gears all back together. My 2nd and 5th gears looked really good. The only thing showing any amount of wear was the first gear wheel (2h7-17211-00-00). All I did was move the spacer to the other side of 2nd.
One thing that helped me out alot was one of those magnetic wands. i had my engine upside down and trying to get those forks in was a real bugger.

Hey there Beech,

Are you saying that you just inspected your gears, moved the spacer, and that was it, didn't replace any gears or do any grinding on the dogs/slots??? If that was all you did, you might want to pull the gears and do some grinding on 1st while you still have it apart!? And 2nd and 5th are easy to undercut while you're at it, could save you lots of time/money/frustration down the road!? IMHO!! Good luck!

T.C.

[beechfront]

grinding on those gears scares me - not that i don't think it's a good idea, but i don't have the steadiest hands and would probably screw something up.

[TopCatGr58]

Doing the Grind.

Hey Beechfront,

I was worried about doing mine at first, and until I found the XS11.com site, and the excellent tips by Ken Talbot and others, wasn't sure just what I was going to be grinding?? The dogs and slots are not the same critical mating surfaces as the actual teeth of the gears. Have you read the several pages and addendums on that site? I wrote some extra notes and provided some decent diagrams as to what is actually being ground, and how to attain the undercut angles and such, it really isn't as critical as everyone seems to make it out to be!! I used a caliper/ micrometer to measure the thickness of the dogs to grind them to similar thicknesses, but that was all!! You're only grinding on one side of the dogs, they're already matched, so taking the same amount off of each one keeps them matched!! And the slots are just as easy, the grinding stone/wheel fits right inside the slots, just a few runs of it in the slot to make the undercut is all that is needed...this is for the 2nd-5th gear fix. The 1st gear is a bit more challenging, but can still be done. A few bucks on some grinding stones was a whole lot cheaper than several hundred on new gears!! IMHO!! Okay, hope yours behaves, but this 2nd and 1st gear malady is REAL, and will happen eventually!!

T.C.