countershaft gears back in

[jmcmillan40]

ok i dont see how to get countershaft back in.
main drive gear and 1st, i cant get them past the last gear on the main shaft?
help?

[DGXSER]

A method I have used to help these gears into place, is to let 1st gears bearing slide out so it can move around more, when it gets into place slide that bearing back into place.

[jmcmillan40]

ok well

i cant get the end down into hole becuse last maingear wont let 1st past

[DGXSER]

Yes, you have to almost completely slide the middle driven gear (the one on the end) off the shaft to the point it is almost not locked into the splines. More or less, slide the gears of the shaft. This is the most difficult part of the project (typically).

The first time I did this repair, this is where I got very frustrated and concerned I would never get it back together. I wound up letting it sit overnight, and the next morning took a day of vacation to finishe hte project. Dang thing slid into place like it knew the way. Don't get to frustrated by it, it will go in, you will get it.

[jmcmillan40]

should this be there


does anyone know if i need this star like thing installed, becuase the one on my xj1100 doesnt have it on there and also did some xj1100 come without kick start gear? mine just has cover no gears and i do have a set should i put them in?

also this one is out of a xs1100

[DGXSER]

Whooooaaaa!!! Hold the phone boss, that is the shift drum, not the countershaft that the gears go on. Or have we moved on to a new part here.

I have never had the shift drum out.

[jmcmillan40]

no this is new

no this is a shift drum from an xs1100
the shift drum i have in my xj1100 doesnt have that star thing on the end

[3Phase]

no this is a shift drum from an xs1100
the shift drum i have in my xj1100 doesnt have that star thing on the end

J, that's the shift positioner. There's a spring-loaded rod in the case that rides on it and holds the shift drum in place for each gear so, yes, it's supposed to be there!


Regards,

Scott

[jmcmillan40]

how do i get it out on my xj1100

i removed clip and 8mm bolt on end of shift drum but it isnt going to come out please dont tell me i have to split cases

[jmcmillan40]

ok well hear is my trans with missing gear

ok here is a picture i have 2 questions first see how there is no star gear on the end of the shift drum like in this picture of one that is not installed.
also i dont see any kind of spring thing that that gear would ride on

also see the gear on the main drive thats the gear iam having a hard time getting past to install coutershaft.

[jmcmillan40]

also

this is a pic ftom tranny overview i do see it on the drum but dont see what would engage with it

[CatatonicBug]

That is really strange! Maybe you have a mutated shift drum? I can't imagine how it would have worked at all that way! This is what it's supposed to look like, from that same angle, and this is an XJ too:



The star on the end of the drum engages with a spring-loaded pin, located underneath the drum, in the case itself.

I may be wrong, but I believe you can't get the shift drum out without splitting the cases...

To get the secondary shaft in past that gear on the main shaft, you have to slip the last 2 gears all the way to the end of the shaft (the inner one should slide off the sleeve), and tilt them just a little, to get around the main shaft gear. Try turning both sets of gears back and forth to mesh the teeth. A bit of a tap with a block of wood can be helpful to convince it to go in all the way.

[jmcmillan40]

lol ok

this sucks so some how that gear came off and now i have to remove motor and split cases right?

[Ken Talbot]

If it came out without splitting the cases, it will go back in without splitting the cases. Have you read all the various posts on this topic, expecially the ones about the "reassembly secrets"?

[CatatonicBug]

If it came out without splitting the cases, it will go back in without splitting the cases. Have you read all the various posts on this topic, expecially the ones about the "reassembly secrets"?

He doesn't have the old one out yet. He has a second shift drum.