1st Gear Advice

[kf4anm]

just a few questions before i get the nerve to tackle my first gear woes. i have read through the 2 nd gear problem fix information. i a interested in the dremel fix since that can be accomplished without splitting the case. i am convinvced i either have a dog problem or a shift fork that is out of whack. is it possible to change or correct a shift fork by using the break down procedures listed in the tec center or would that require pulling the motor.
next, the prevous owner of my xj has removed the octopus vacuum system leaving instead each petcock feeding directly to the carbs. therefore i have on and off, and must remember to shut them off each time or risk flooding the carbs. the bike seems to be tuned to run like this pretty well. it runs somewhat rich and the fuel economy is nothing to bragg about, but compared to the cost of retro-fitting the original back into place i think i will leave well enough alone. however, i have the petcock on the right side leaking from the sides. i will have to replace this petcock with a generic aftermarket one theat the bolt holes match. in the meantime until i can find that matching assembly i am considering splitting the other line to feed both carbs. do ya'll think the one line and petcock can supply enough fuel to maintain the idle.
finally, i extend my prevous offer to anyone who wants to come to indy and take on my tranny. labor, food, beer, and a hotel room on me.

[Jeff]

The petcock can be easily repaired using any one of the rebuild kits still available on eBay or Parts-n-More. Sometimes all it takes is a teardown and cleaning to remove grit trapped behind the disc that prevents a good o-ring seal.

[beechfront]

you should be able to get to the shift forks just as easily as the gears without removing the engine. though i took the motor out and was glad i did.

some of these bikes didn't have an octopus, but if yours did - you can buy a replacement for $60 at your local yamaha dealer.

[TopCatGr58]

Other info location

Not wanting to piss off any of the officianados of the FORUM, but if you will go to this site:
Yahoo AllXs11s group

Sign up for Yahoo groups, it's free, then go the files section, look in the Tips & Tricks, you'll find a step by step writeup on the 1st and second gear fix, and lots of pictures and diagrams to assist you in your venture.

I just did my 3rd repair on a 3rd bike, another XJ, and did both 1st and second gears using this method!! Good Luck

T.C.

[TopCatGr58]

Almost forgot, then ran out of time editting!

PS: as for the fuel thing, folks will tell you that running without the octopus is NOT what's making the bike run rich or low mileage, you will need to do a good cleaning of your carbs, ensure you have clean airfilter, no vacuum leaks, inspect the condition of your plugs, and adjust your carbs accordingly, float heights, pilot/idle adjustments, etc.. I even made my own petcock washer from some thick neoprene type large washer from the hardware store, used a single hole punch to make the required holes, worked fine. The outer O-ring might be bad on yours, and I couldn't find one thin enough at the hardware store to fit it, so you may be better off with the rebuild kits!? Mike Hart IIRC or was it Gary Granger that stated that he had done a flow test on a single petcock, and it flowed plenty of fuel to feed all four carbs from a single spout!! Just don't have a big loop of line running below the carbs from the petcock!! Again, good luck!

T.C.

[kf4anm]

thanks for the info. i am hesitant about taking it down this early in the summer but am afraid it is going to have to be done. thanks also for the petcock info. i think i will try to run temporarliy on one feed but am going to look into 2 new replacement petcocks one for each side that have on or off selections. the bike runs pretty good on the non octopus set up. i've drove my self crazy dorking with my 650 kaw carbs and don't want to upset the balance on the xj. 1st gear may be shot but she will still come screaming out of 2nd @ 65mph and be no where near the red. i've got my fingers crossed for a bent shift fork with no actual gear problem but i'm sure that aint happening.

thanks again

[CMA1]

<< i think i will try to run temporarliy on one feed but am going to look into 2 new replacement petcocks one for each side that have on or off selections. >>
Kf4anm... sir, did you find the replacement petcocks for your application, yet? This is the way I am thinking of going also. I had someone else rebuild the carbs once for me, but they have obviously not been careful enough and the petcocks, octupus arrangement needs work on my SF. I don't have difficulty with remembering to shut off the taps when I stop (was taught that habit) and if I do forget, and it leaks, then I will know it is my fault! not the guess work starting all over again... the Octopus? the petcocks?... the floats?... etc.........
Thanks for your response.
Larry

[kf4anm]

petcocks

what i found with my petcock situation was i had one original and one from lord knows what bike. both were feeding straight to the carbs. i though i could use the 1 original and feed both but to my suprise you can't make both feeds flow at the same time since 1 is for the prime and the other attached to the vacuum system. i talked with my local cycle expert at cycle recycle 2 and his feelings were if its running okay without the octopus let it be. i pulled the odd petcock and took it in. after fumbling through his box of used petcocks i discovered the odd one came from an 850ish suzuki. he had a set of the same kind that the holes lined up and were in decent shape. (he had an original xj set but they looked like they had been sitting for 15 years in a dirty gas tank.) the ones i bought ($40 a pair) have the vacuum line built in. they fit fine i left the vacuum lines plugged and run on prime all the time. i had to modify the left side a touch the fuels feeds out at 6 o 'clock and the vacuum at 3 this put it right into the airbox. i took a utility knife and trimed the airbox a touch and the tank sits on the frame fine. i installed new fuel lines and filters and haven't had a lick of trouble since. i have gotten into the routine of every time i shut it off of reaching down and shutting off the fuel. as long as i do it everything is kosher. i've been running on the new cocks for about 3 weeks now and for the money it was the perfect fix.

octopus free xj and loving it
daryl

[Jerry]

A lot of people shut off the petcocks to avoid flooding. Personally, the only time I shut mine off is for winter storage. Since I lived the past 2 winters in Arizona, I haven't shut the petcocks off in almost 3 years.

If shutting the petcocks off solves a flooding problem, the issue is not the petcocks but the carbs. The float needle/seats should shut off fuel when the fuel level reaches a certain level. If the needle/seats are not shutting off fuel, they are not working properly when the bike is running and the petcocks are turned on. You are loosing performance and/or mileage. Ask the people who have set their float hight correctly what a difference this makes.

Granted, shutting off the petcocks will save you from loosing gas on the ground, or worse, having it end up in the crankcase. It is not the complete fix, though, and I encourage people using the petcock shut-off to avoid flooding to do the complete fix by replacing worn or damaged float needles and seats.

[CMA1]

Thanks very much for your replies.
I am surely going to have the carbs apart and want to get the whole thing working together. I understand the safety issue of the vacuum controlled 'octopus' set-up and I understand the warnings about 'shutting off the fuel everytime' I stop the bike... that has become a habit with me anyway.
I am going to try the link Dlbryant provided, but if the Suzuki taps work well and are that much cheaper, it may be the prudent way to go.
Thanks for all the help and suggestions... this board is a special place ('Special' !!!! hehe)
Larry

[fusionking]

I got all my stuff working correctly, but I STILL do the petcock thing. I seriously don't trust those little sping loaded needle valves. Never had even a lick of trouble........don't want any either. If I trusted them, the first time I really needed my bike I just know they would let me down.....or so it would seem. Has anyone tested the effect of the sidestand VS centerstand on float leakage? You'd think leaning could effect it.

[kf4anm]

leaking

mine leaked in 2 places before i changed them out. the right side leaked around the back seal when the bike was running and the fuel on. the left side would leak with the fuel off and the bike on the sidestand. i don't have the room to use my centerstand in my shed so when i parked it i used a small 1 by 4 under the side stand to straighten it out. that seemd to work pretty well.