XJ11 - Transmission noise & Getting into gear

[Prothec]

I finally finished rebuilding my XJ11 and have it on the road.

At this point I have a few questions. I'm not sure if most of my "concerns" are because I'm used to riding my XJ650.

1. At any point when I have the clutch engaged and slowing down there's a whine - the first time I heard it I looked around to see if a police car had their siren on.

2. When accelerating hard, getting into the next gear can be rough. Example: when accelerating through the gears, I get chatter trying to get it to shift into the next gear.

I don't have any experience with clutch issues, but it seems to not want to shift from 4th to 5th with the throttle completely off and the clutch disengaged.. clutch drag?
Everything feels good at low speed going from 1st to 2nd.

When going from 2nd to 3rd when accelerating seems to be easy to find yourself between gears.

For full disclosure, I didn't do any gear fixes and when everything was apart everything was in good shape.

3. When downshifting coming to a stop, it feels like I've shifted back down to 1st, but found myself trying to take off in 2nd. It feels like the only way I can make sure I'm in 1st is if I continually try to downshift.

4. I don't have any turn signals at the moment. My flasher relay disappeared during the rebuild when we swapped out the wiring harness. Anyone have any suggestions on a 2-prong automotive flasher to use instead? Hopefully I'll find the original at some point.

Things I still need to address:
- Somehow I think we missed the gasket on the right side cover. I have a small oil leak there and have that gasket left over

- The softer fuel lines I used tend to kink easily - I put springs around them at the petcocks to keep their shape, but found another area was kinked this morning when I took it out around the neighborhood.

- Clean up all the chrome and rust and touch up the paint

- Re-connect the brake level switch and fuel sender unit

- Get turn signals working

- Swap out the inline glass fuses with TC's fuse box


Overall the bike feels good and I'm happy with the end product

[DGXSER]

Lets try and take this one piece at a time...

1. At any point when I have the clutch engaged and slowing down there's a whine - the first time I heard it I looked around to see if a police car had their siren on.

while a shaft drive bike does have some gear noise in decel as well as accel, but engine noise tends to drown it out, I'd check both the middle drive and final drive gear oil levels. Also, make sure you remove the final drive and grease real well inside where the shaft slides into the coupling. That grease fitting on the swing arm is not of much use as it does not get the grease inside the coupling where it really needs to go. You will fill the entire swing arm back to the u joint and not get it into that coupling. I've seen it tried on another XS11 before (or so it appeared for all the grease all the way up the drive shaft).

2. When accelerating hard, getting into the next gear can be rough. Example: when accelerating through the gears, I get chatter trying to get it to shift into the next gear.

Not sure if you meant this is good in 1st and 2nd or not. The chatter effect you describe is the tell tale sign of the 1st and or 2nd gear issue these bikes are notorious for. Otherwise, could be clutch adjustment required, which should be the first step anyway.

I don't have any experience with clutch issues, but it seems to not want to shift from 4th to 5th with the throttle completely off and the clutch disengaged.. clutch drag?
Everything feels good at low speed going from 1st to 2nd.

This sound sliek a clutch adjustment issue. Read the tech tips on how to adjust the clutch cable on BOTH ends. Do that, and see how it goes.

When going from 2nd to 3rd when accelerating seems to be easy to find yourself between gears.

Yep, you really have to shift like you mean it with these bikes. A toe tap does not get it into the next gear but can and will take it out of the one it was in. Be sure to pull the shifter ALL the way up on every shift.

[For full disclosure, I didn't do any gear fixes and when everything was apart everything was in good shape.

I once got a dog form the pound, looked so calm and nice and lovable....one year later he was put down cause he would attack his own shadow just because. Looks can be decieving, see item one above.

3. When downshifting coming to a stop, it feels like I've shifted back down to 1st, but found myself trying to take off in 2nd. It feels like the only way I can make sure I'm in 1st is if I continually try to downshift.

There is a return spring on the shift lever. If you pull the shifter side cover off (looks almost rectangle, has a hole the shifter comes through) right under that cover is a spring on the shifter shaft that goes around a steel rod. That spring can get weak and not pull the shifter all the way back giving you a "short shift" on the down shifts. Might want to replace that spring.

4. I don't have any turn signals at the moment. My flasher relay disappeared during the rebuild when we swapped out the wiring harness. Anyone have any suggestions on a 2-prong automotive flasher to use instead? Hopefully I'll find the original at some point.

I've not done it, but plenty here have. Alot of different auto 2 prong flashers will work though. However, you lose the self cancelling feature. I have a spare flasher relay If your interested in it.

Things I still need to address:
- Somehow I think we missed the gasket on the right side cover. I have a small oil leak there and have that gasket left over

Do you mean the clutch cover gasket? if you missed the entire gasket, you should have alot more than a small leak in one spot. Put the bike on the side stand and pull the clutch cover back off (on the side stand the oil is low enough you do not need to drain it to do this).

[Overall the bike feels good and I'm happy with the end product

Good job, feels good to ride a machine you built.

[bikerphil]

Also check the shifter pawl alignment as described in the service manual. If the marks do not line up, improper shifting will result. Hope it's somthing as simple as this.

[Prothec]

Thanks for the info.

There is a return spring on the shift lever. If you pull the shifter side cover off (looks almost rectangle, has a hole the shifter comes through) right under that cover is a spring on the shifter shaft that goes around a steel rod. That spring can get weak and not pull the shifter all the way back giving you a "short shift" on the down shifts. Might want to replace that spring.

I actually couldn't find the return spring and got a new one.

Edit: Not just now, I mean when we were putting it together!

I've not done it, but plenty here have. Alot of different auto 2 prong flashers will work though. However, you lose the self cancelling feature. I have a spare flasher relay If your interested in it.

I just found the 2-prong 4-way flasher and I now have turn signals!

Do you mean the clutch cover gasket? if you missed the entire gasket, you should have alot more than a small leak in one spot. Put the bike on the side stand and pull the clutch cover back off (on the side stand the oil is low enough you do not need to drain it to do this).

Yep, the clutch cover gasket. Considering I have it left over and can't see a gasket, it must not be there
I don't know how we missed it... Overnight I had a very small puddle.

[Prothec]

I checked my middle drive and yes, it was quite low. I added to it and took it for a spin and the shifting feels much better. Thanks DG!

I had one of my neighbors a road over yelling at me as I rode by to slow down as I hit 25mph. I think he meant to yell "ride quieter".

I finally have a bike I can piss off the neighbors with

[DGXSER]

Awesoem job finding the problem!! Hope it brings you many miles pissed off neighbors!

[SFerinTEXAS]

I checked my middle drive and yes, it was quite low. I added to it and took it for a spin and the shifting feels much better. Thanks DG!

I cant see how oil level in the middle drive would have ANY effect on shifting, Anyone want to explain this to me?

[Prothec]

Good question - I can't imagine it would, but I'd rather ride with than without It could just be the placebo affect, but on the ride home from work today the only problem I had was the 2nd-3rd PITA.

More work to add to the winter todo list...

[SFerinTEXAS]

Haven't had a chance to address you directly. Would like you to know I have followed some of what you have done and am quite impressed.

Assume you also checked the final drive level as well. Really should drain and refill both gears with 75w90. Might be sludge or water in there. Search dipstick for the tool template if you don't have one

[Prothec]

I appreciate it! This has been an amazing experience. I spent an excessive amount of one-on-one time with an experienced mechanic using his tools and learning his tricks.

I double-checked the final drive oil and all is good. It got me thinking to check my 650's final drive..... sludge.
I ended up putting Valvoline 80w90 synthetic blend in both - pretty much all I could find on labor day.

I used the template and cut a couple gauges out of a plastic coffee can lid


Next question:

My tach is very slow to respond. Any idea why this would be? I was hoping it would get better after riding it a while. So far it hasn't changed.
Again, I'm used to the mechanical tach on my 650, so not sure what to expect.
If necessary I can get a video to show what I mean.

[79XS11F]

I appreciate it! This has been an amazing experience. I spent an excessive amount of one-on-one time with an experienced mechanic using his tools and learning his tricks.

I double-checked the final drive oil and all is good. It got me thinking to check my 650's final drive..... sludge.
I ended up putting Valvoline 80w90 synthetic blend in both - pretty much all I could find on labor day.

I used the template and cut a couple gauges out of a plastic coffee can lid


Next question:

My tach is very slow to respond. Any idea why this would be? I was hoping it would get better after riding it a while. So far it hasn't changed.
Again, I'm used to the mechanical tach on my 650, so not sure what to expect.
If necessary I can get a video to show what I mean.

If the tack is moving slowly, twist the throttle faster Works for me
Rob

[Prothec]

If the tack is moving slowly, twist the throttle faster Works for me

If that's all that's wrong, I have reason to fear this bike

OH.. I can't believe how easy it is to get this beast on the center stand! I have to fight with my 650. Much more so when I forget to take it out of gear