Special tools for 2nd gear fix...

[gareth]

OK.
Todays the day I tear into the SF to fix the second gear/skipping problem.
I have most of an additional transmission available, including a fully repaired/modded/undercut countershaft supplied by another member. The replacement gears and dogs look good so I won't have to do that part of the job.
I am just about to head to the local autoparts supplier for last minute stuff.

In addition to a t30 torx bit, a can of the Right Stuff and standard tools, is there anything else that I need? What is the size of the big clutch nut?
I am going to try and do this on the centerstand, starting later today and all day tomorrow if it comes to it...

Just don't want to get stuck being "nearly there.." for lack of a thing-or-two...

Regards,

Gareth.

[DiverRay]

IIRC, the clutch takes a 25mm. DO NOT take my word for this, as it's been over six months since I've been into a clutch. You WILL need an impact tool, air or hand, for the clutch nut. A chisel wit ha slight hook or bend at the end will help with the look washer when you put the clutch back together.Good luck!

[Rasputin]

I think that nut is a 27mm, but would have to check when I get back to the garage.

[bikerphil]

Clutch nut is 27mm, or an 1 1/16" will work. You can use the rear brake lever with the bike in gear to hold the engine from spinning to break loose the nut.

[gareth]

1 1/16" socket worked well...the nut was not very tight at all, very little pressure needed to move it. Without the locking tab in place, that sucker would never have stayed put. It's going to be interesting to see what kind of job the PO did when he did the dremel fix the first time..

G.

[thecamelman79]

dremel chainsaw sharping bits I used 3
dremel tool
a 1/8 round ball tipped carbid bit from fastenal would be nice too.
I ground mine using the drill press too, made a nice edge to keep the angle consistent.

Lots of beer or coffee

ditigital camera so you can remeber where everthing goes, I use it on almost everthing I take apart, although it never fails that I alway forget to take a pics of what I cant remeber

[gareth]

All apart, replacement countershaft is being a huge pain to reinstall. This seems to be a typical problem that most people eventually overcome. I'm having a LOT of trouble. I have read a bunch of tech tips on this after numerous different searches and still waiting for my "ah-hah" moment.
The kickstart mechanism isn't helping any..

Can the kickstart mechanism/ gears be removed and then reinstalled after the countershaft is in..?

The bike is on the centerstand.
I'm on my back cussin' up a storm with all the stuff 3" from my nose..
I'm going to give it another shot tonight , then leave it for tomorrow. If it doesn't go right, then I will consider flipping the bike rubber-side-up.

G.

[DGXSER]

Hey Gareth,

The first time I did this project, I spent hours trying to get that bloody shaft back in. I figured out that for me anyway, I slide the middle driven gear, and the 1st gear out to the end of the countershaft, fist gear slides off the inner sleeve bearing as well. This lets them rock on the shaft so they can slide up into place and mesh with their corresponding gears. Then I carefully slide line the shaft up with the teeth on the middle driven gear and get the sleeve bearing started going back into first gear. Now, slowly rock the back wheel back and forth with your foot while you wiggle, push and jiggle the shaft and gears. then just when you think it iwll never go in, it will. And you will be left thinking "ok, WTF did I do differently that time??" And you will never know for sure.

[jetmechmarty]

I left my bike upside down with the countershaft uninstalled. It was time to go to work. Trouble is, I might not get home until 21 Feb. I hope I can remember where everything went! The good news is, I'm in Jamaica!

[James England]

If you did the washer switch, you'll be on your back an awful long time, I'd say.......

[gareth]

Long day, bike is back together and seems to be shifting through the gears under power but I have only run it on the center stand. I will see if the weather will allow a test ride this week. I learnt a lot and could probably cut the work time in half next time. I did have a decent countershaft that Papanovember sent me that had the dremel fix already done (by trbig..). The original countershaft didn't seem that bad but the shift fork that moved 5th gear was badly galled and I suspect that was a big part of the problem. I was glad I had a spare tranny set aside just to use for parts. The replacement shaft has all the gears undercut and apparently the washer fix was done too..
I removed the kickstart. As I mentioned in another thread, the kickstart gear has to go in at the same time as the countershaft but it made installing the new gears a real pain. If I was to do it again I would pay a bit more attention and save the kickstart. Don't get me started on getting the shift forks to play fair...

This might have been the most complicated piece of wrenching that I have done in a while. There's nothing like assembling a complicated three-dimensional metal jigsaw puzzle, upside down, on your back, 4" from your face, with oil dripping down your neck. Next time I would flip the bike..

Feels pretty good, though, to have it done.

Jeez, I just hope it works when I gun it.

Thank you, Gentlemen, for your advice...

Regards,

G.

[DGXSER]

Congrats Gareth!! This is one of the real chalenges into "official" XSiveness!! (just kidding of course) But it does feel pretty darn good to get it all back together AND work well!!

[Brent]

Super human

Don't get me started on getting the shift forks to play fair...

This might have been the most complicated piece of wrenching that I have done in a while. There's nothing like assembling a complicated three-dimensional metal jigsaw puzzle, upside down, on your back, 4" from your face, with oil dripping down your neck. Next time I would flip the bike..

Feels pretty good, though, to have it done.

Jeez, I just hope it works when I gun it.

Thank you, Gentlemen, for your advice...

Regards,

G.[/QUOTE]

Gareth,
I am impressed! Helping Marty remove the counter shaft & gears from his upside down bike was hard enough. I told wife I doubted that any mortal man could reinstall them from underneath. It is a miracle or you are super human. You should be proud.

Brent

[gareth]

Thanks for the kudos, Brent. Nothing superhuman or miraculous. You just need to be able to wiggle out from under your bike, stand up and find the bolt-gear-tool that you couldn't find by feeling around from hip to hip over your head, switching arms mid-way. Find said object exactly where you had positioned it so that it was just outside your reach...and then get down on the floor under the bike again.
Repeat 500 times

[ThrottleJunky]

How do you guys safely flip your bikes over without damaging anything?