grinding noises in the gears

[CavBird]

i just got a XJ1100 and there was some grinding and sticking in the first gear, so rode it home as best i could starting out in second almost the entire ride was on the highway in 5th gear so figured it wouldnt be to much of a problem... by the time i got home 2nd gear was also making alot of noise and grinding

im assuming i will have to rebuild the xmsn... any tips or anything else to look at?

[DGXSER]

A few options here.

First, did you make sure and shift "with authority"? These bikes need a firm foot and a "full pull" every time to shift right. Solution is shift purposefully.

Second, was it a grinding, or a skipping? Did it feel almost like a machine gun hitting (going in and out of gear)? Could be the infamous 2nd gear/1st gear problem. See tech tips under repairs/ transmission for 2nd gear dremel fix.

Third, could be bent shift forks. Tends to happen when a PO holds the gear in with the shifter when it starts to skip as in problem no 2.

If it were me, I'd start by getting into the tranny as described in the dremel repair tech tip. See what you find there. IF everything else is good ont he bike, this could save you alot of time and effort in not pulling the engine and splitting the cases.

[CatatonicBug]

Welcome to the forum! Sounds like you have the standard issue with the XS/XJ transmission. I have had to do that fix on (in order) 3rd, 2nd, AND 1st gear - all 3 separate times! It's really not that difficult, and will take an inexperienced guy like me a full Saturday afternoon/evening to do it all by himself. Be sure you have a manual (available in my signature) and the tech tip that walks you through the process (with pictures!). Have fun!

Oh, and we like to see pictures of the bikes we're talking about! Let us see your new ride too!

[trbig]

As DGXSER stated, if you put it in gear and it skips... basically going in and out of gear, then it's the gear problem. If when you have it in gear, you hear a grinding noise like gears spinning against each other a bit, then you have a clearance problem for some reason. I would also guess bent shift forks. They are a light cast aluminum and will easily bend. These keep the spacing right between your gears for the most part.

Another obscure problem I have had, was on the shift drum, there is a lock washer that holds a stopper plate in line. It got cocked sideways, making it hard to shift and not letting the shift drum be in the correct position exactly, causing the forks to hold the gears in the wrong place and letting them mesh a bit. You can see the offending stopper here cocked.. next to the clip I am pointing out . You can also see the shift forks and how they hold the gears.




No matter what the actual problem is, it does look like a transmission fix is in order. If you happen to have the clip loose on yours also, this unfortunately does require the cases to be split. Sounds daunting, but it really isn't.


Tod

[CavBird]

to me it sounds like someone snuch some gravel in there while i wasnt looking... i will do the dremel steps hopefully that fixes it... dont want to have to crack it completely open if i dont have to

the new addition....

[trbig]

There's actually a member here named Prometheus that is.. I hate to admit.. a very accomplished mechanic that lives in Olympia. He unfortunately isn't on here much any more, but I know he peeks in every now and then. You might try a PM to him and try to bribe him with some beer to stand and point while you do your work. At least tell him that... he usually can't stand to not get his fingers greasy after a while.

BUT.. if you don't hear from him, you can probably come on here to ask any questions you may have. If your job requires a case split... it's really not that big a deal at all.

Tod

[CavBird]

eurika!!!...

i just finished the prepto be ready to flip the bike for the dremel steps.... while getting ready to take off the cluch basket i saw alot of metal flakes so i am thinking i will have to replace a few gears at least

then i took off the cluch basket and i found



going to still flip the bike... see how much more damage there might be..
wish me luck... i will let you know if i find anything else

[latexeses]

That'll do it!

[CavBird]

i think i figured it out... i think its my countershaft bolt... andyone know a reason for it to be laying there other than poor maint?? off to the parts store....

[Bigfoot]

Well, that probably explains alot of your grinding noise. And yes, that is the bolt for the countershaft. The tranny is easy enough to get to that I have never bothered flipping the bike. Just seems to be alot of extra work to me.

[Ivan]

I have had that happen as well.

Get a can of carb cleaner, and clean the threads of the bolt, and the threads in the countershaft. Then use RED loctite, torque and give it an hour or so before starting. I have tried blue and it just doesn't cut the mustard.

Also, I am guessing you probably don't have much else to rebuid, unless your second gear is popping out.

[CavBird]

yes i figure that was my problem right there... but the bike is flipped so i figure mught as well look at it... wont hurt anything... i think i need a new bolt... then definatly locktite... but that will be for tomorrow... then i just have to worry about the breaks and the rear wheel LOL

[DGXSER]

Yep, definitely the countershaft bolt. Someone must have put it on but forgot to torque it down. Perhaps it is a good sign that the dremel fix has already been done though?? Not sure it would give me confidence in who did it though.

If it were me, I'd get the replacement bolt. I'd also want to run a tap back in the countershaft to be sure the threads are decent in there. Ivan's suggestion of Red locktite is also a good addition based upon the messed up threads.

[Ivan]

If it were me, I'd get the replacement bolt. I'd also want to run a tap back in the countershaft to be sure the threads are decent in there. Ivan's suggestion of Red locktite is also a good addition based upon the messed up threads.

Yes on the replacement bolt. The one you have will not hold.

Not no but Hell NO! on the tap. That shaft is harder than hell's bells and the tap will break very easily when trying to back it out. The only way to fix that is take the bearing cap off the other side (under the shift cover) and use a punch to drive the broken piece of tap through and out the other side.

Anyone care to ask how I know this?

[trbig]

I've had this happen also... Yup, you'll need a new bolt, but it's not something you can pick up from the parts store. You'll have to find a used one.


Tod