dremel tool fix

[brcree]

Ok guys, here it is so far: Bike is upside down....trans pan is off. Rotated rear tire......first gear missing 3 teeth!!!!!....now...my question is....with only 12,000 miles on bike will the need for the dremel job be necessary? Should I go on and purchase a newer gear set/drive........and hope its ok or, do the dremel fix on the new set of gears to make sure my problem is gone?

[CatatonicBug]

Check the new gears. They may already be under-cut. If they are not, I would do it before installing them, along with the washer swap (I know not everyone likes the washer swap mod).

[brcree]

Dremel fix.....

Does anyone have complete pics of gears after the dremel fix?

[CatatonicBug]

You mean like the ones in the Tech Tip?

[brcree]

I already have copied that ....I need pics of the finished gears....to see what the fix looks like.

[DGXSER]

At this point your options are to buy a new gear or new gears at a cost of about $100 a gear. Or buy used gears. The new gears typically are already back cut the same as the dremel repair would do. Used ones may not be. So you may need to beack cut them after you buy them.

I would not put a set of used gears in without dremel cutting the back cut into them.

I would go ahead and finish pulling the countershaft out and see what the rest of the gears and the shaft and shift forks look like. Then you will have the full picture of what you are up against.

If you find you need parts,let me know, I have the entire transmission out of Thunderstruck sitting on a bench waiting for a new home.

[DGXSER]

Here are some of the after repair pics on the ones from Thunderstruck.

5th dogs after cutting


Side view of 5th


2nd gear slots after cutting


5th gear dogs after cutting top view


The angle is very slight but you can just see it. The pics are a little fuzzy, the cam is not that good at close up photography.

[prometheus578]

I just merged your two threads so that your progress (and questions and answers) can be followed easier.

[brcree]

Dremel fix

Thanks guys.....well i've found a few sets of used gears on E-Play but they dont look the samre as mine, gear size that is. Do all xs 1100 gear sets work for all 1100 years?

[DGXSER]

Yes, the gears in all XS1100 and the XJ1100 are the same.

You may need to watch if they are selling the main shaft or the countershaft. The gears that are pulled and cut in the dremel fix are the countershaft set.

[brcree]

Thanks DG.....big help!

[DGXSER]

If you decide to bid on something on ebay, post a link here first and one of the members can help you be sure your getting the right parts.

[Guy_b_g]

Sometimes you get lucky on Fleabay...I bought a used parts grab bag a couple of years ago that included the transmission, and it had the factory undercut gears in it.

Some of the bikes that had gear repairs done are coming up for parts auction these days, and maybe if you ask the right questions of the seller, you can find a set.

Just a thought

[brcree]

Thanks Guy,,,,DGxser is hooking me up with a set already done......you guys are the best! Hope I can help someone out like this sometime!