2nd gear problem

[Chris1]

Looking for local shop or member who can help me repair my 82 XJ1100 with the 2nd gear problem. Anyone in the southern Wisconsin area?

[DGXSER]

Not in the area, but if you go to the top of the page there is a drop down under "XS11 INFO" titled "Tech Tips" from there go to "repairs" and then to "Transmission". 1st article is the one you want. Gives you a complete play by play walk through on how to make the repairs yourself.

[BossMaverick]

I'm not trying to hyjack the thread, but how difficult is the gear fix (compared to something like changing the cam chain)? Is the Tech Tip article make it seem more over-whelming than it actually is?

[psycoreefer]

The 2nd gear fix was the first motorcycle repair I ever did, I'd say that its on about the same difficulty level as replacing the cam chain. If you follow the tech tip and you have some mechanical ability then its hard to really mess things up. Id say the most nerve racking part for me was dremeling the old gears, because once you do there is no going back. Of course you could avoid that by buying new gears from Yamaha.

[DGXSER]

Boss Maverick,

It is not a cake walk, but it is not that hard either. I had alot more trouble changing the timing belt on a V6 Camry than doing the gear repair. In my estimation, like psychoreefer stated, if you have some mechanical skills and ability, you can do it with out to much trouble. If you do not, then it will be more of a learnign experience and harder, but it is still doable if you have the will and determination and ask all the questions you need to here.

To me, the hardest part of the process is getting the gears back into the engine. I did mine on the centerstand, so it may be easier with the bike flipped over. I had almost no problem getting the forks back in correctly, and the tech tip makes that sound hard. Go figure.

[Chris1]

DGXSER & psycoreefer,

I was thinking of going the route of just replacing the gears that need to be replaced. Not trying to waste money, but I only want to do this once. Has Yamaha corrected the gears so that this problem will not happen again. My bike only has less than 17,000 miles on it and it really chatters when I get over 3k rpm in second. I think I have the tools and the skill set to get this done, but time is always a factor. How long does this take to complete?

[DGXSER]

Yamaha has produced the gears with the same back cut that the dremel fix will put on them. They run about $100 a gear and will require a minimum of 2 to fix the 2nd gear (2nd and 5th gears).

The dremel work will take about 2 hours to grind the gears and, from my experience it is not like they have to be micrometer acurate in the cutting. I used some clay to check the angle of my cuts (like plastigage for bearing clearance check). And I have had no problems. You can also back cut 1st and 4th while you are in there which are easier to do in my opinion, and save yourself another $200 and/or trip into the tranny.

The total repair will take about 14 hours of work. I guess about 4-5 hours to pull the gears out. A couple hours of grinding gears but I would do this as a separate evening of work, take your time and remember you can always take more off but it not easy to put material back. then about 4 hours to put it back together. Of course your experience and how quickly you find the right place to hold your tongue so things go like they should will vary the time required. It is strongly suggested and I agree (now that I have to go back in and do it later) that you replace your clutch springs and perhaps your shift return spring while your doing the work. You will have everything torn down to the point it is just substituting parts you put back in anyway.

[psycoreefer]

I'd offer to help but I'm in grand rapids MI, if you want to hop the ferry, ride the bike over etc I have a garage we can work in we can have it done in a weekend. I supposed we could do the other way to if you want to pay for the travel I could come to you. Really though if you can follow directions and have the tools its something you can do. If you get stuck there is lots of help here.

[Chris1]

Thanks guy's. I am pretty sure I can handle it by following the directions. I have the tools and just need to find the time. I just got it running about a week ago, PO had it sitting for about 2 years and had to clean the carbs and order new parts (carb holders, gaskets, needle/seat, jets, fuel filters) got it running pretty good, just needs sync and valves checked. It likes to pop a bit under deceleration, not sure if I have a leak in the exhaust, the exhaust system looks like new (no rust or pitting), but I guess after 27 years it could be the problem. I guess I should replace all the muffler gaskets to eliminate that possibility. Any other ideas on the popping? It does not do it all the time.

[TopCatGr58]

Hey Chris,

Due to the XJ's YICS system, synching can not be done properly without a YICS block off tool. In the parts for sale Forum, Sticky, you'll find a product called the YICS eliminator, can be installed and LEFT IN PLACE after Synching. Tod recently replied to another thread regarding the merits of the YICS vs. blocking it off.

Perhaps you mean the header gaskets, they could compressed and lost their seal, new gaskets would probably help, but first may just need to tune/synch the carbs and turn the pilot screws out a 1/2 turn or so more to richen the pilot circuit a little so that it won't be so lean when you back off the throttle during DECEL!
T.C.

[Chris1]

Topcat-

How far should the airscrews be turned out. I have them at 2.5 turns out right now accross the board. I am going to take it to a local shop for some fine tuning, they have the YICS tool and (because I do not have the time). Additionally it does not like to start and run on all 4 cylinders, 1 and 4 will not fire until it warms up a bit (30 seconds) and the choke is almost off. I checked the spark with a timing light and all 4 are firing, but runs rough and will not idle properly (1150 rpm) until it's good and warm. Carb holders are new and air box boots are all in great shape (Stock air filter and box) I am not sure if I have it to lean, but I would think it should run on all 4 when cold and choked. Once it is warm it runs great and idles perfect. Very strange!!

Chris

[trbig]

They run about $100 a gear

You better check your price guide on that...

Tod

[Bigfoot]

I priced 1st and 4th yesterday just for kicks at a local dealer. With tax they would have run about $200 each Ground mine and seems that I finally got it right.

On second, don't forget to swap that washer, made a world of difference on mine.

Also, you can make your own YICS tool very easily. Do a search and there is a post with detailed instructions. Make sure you use Viton hose for it though.

[cruiser]

Check here
http://www.highlandsyamaha.com in Countryside IL.

In stock:
SKU: 2H7-17221-01-00
GEAR, 2ND WHEEL (39T) 1 $125.78
SKU: 2H7-17251-00-00
GEAR, 5TH WHEEL (30T) 1 $149.31

[Chris1]

http://www.boats.net/parts/detail/ya...221-01-00.html

$112

http://www.boats.net/parts/detail/ya...251-00-00.html

$133

I have used this supplier a couple of times. Great prices for OEM Yamaha parts.