Transmission what about third gear prob

[kitt04]

I have a 78 XS1100 I rebuilt the trans yesterday to fix 2nd gear IT WORKS GREAT but for some odd reason now I have a third gear problem IT jumps when throttling about half or more. If I throttle easy its fine. I do have a the carbs slightly unmatched it idles a little unsteady could that have something to do with it or could I have possibly done something wrong in the trans when I did it

[XJOK2PLAY]

Hi Kitt04...
Depending on what approach you took, whether you chose to do the dremmel backcut of second or you replaced the gear...
one thing all the tranny guru's here will tell you, while you were in there and had the cases split, that's the time to backcut all of them so that this doesn't happen, cause that always seems to be the rotten luck. Especially with all the work one goes through to do the repair.

There is always the possibility a washer or something simple may not have been reassembled properly, but what your describing sounds like 3rd needed attention as well. The dogs get worn down on the edges and causes the slip under torque.

Doubt seriously if carbs have anything to do with the problem.

Sorry to be the bearer of bad news, but my guess is you'll have to operate again.

[DGXSER]

The vibration may be synchronization of the carbs. I'd try that first.

The third gear issue sounds like the others have stated, one more trip into the great white abyss of the tranny.

[TopCatGr58]

Hey there Kitt,

Sorry to hear about 3rd gear. It's surprising to hear that it's causing you trouble, because unlike the other gears, 1st, 2nd, 4th, and 5th, the 3 gear dogs are actually dovetail/undercut at the factory. I showed Bigge_Al that when I pulled his gears out to fix his 2nd gear problem. However, if the 2nd gear problem was present for quite some time, then a PO may have gone to using 3rd sooner, and put more stress on it, wearing the dogs on it faster??

I have seen/heard of a few folks having the 3rd gear skip problem, but it is much more rare than the 2nd and 1st gears. BTW, did you inspect and dress/undercut the 1st/4th gear dogs/slots while you were in there?? IF not, then you were playing roulette anyways, because if 2nd was a problem, 1st wasn't far behind!

Did you do the washer swap? I don't do it on the ones I fix, I feel the undercutting does enough and keeps them pulling together. I don't even know/remember when it's swapped where it ends up sitting, so I don't know whether it might interfere with the 3rd gear engagement?
T.C.

[kitt04]

3rd gear

Thanx for info I did do 4th and 2nd while in there I do not know what you mean when u say washer swap but I guess it will be soon back to the tranny board

[petejw]

Kitt,
was your 3rd gear working fine prior to doing the 2nd gear repair?
how far down did you strip the countershaft gears?
Did you adj the shift pawl correctly?
could be a misplaced washer.

[DGXSER]

Hey TC,

The washer swap takes the washer that sits between 2nd gear and the retaining C clip on the 5th gear side, and slides it to the other side of second. This essentially moves 2nd gear closer to 5th, and leaves second gear riding against the retaining clip instead of a washer on that side. The other side of second gear has a collar machined into the countershaft that holds it. So the washer swap would not seem to be able to effect 1st, third or fourth gears.