2nd gear fix done, putting back together stuck (strong language)

[Wouldstalk]

FFFFFUUUUUUUUUUUUUCCCCCCCCKKKKKK!!!!!!!!!!!!!

A little under 6 hours and the Gear rack was removed, the 2nd gear dremel fix done and the washer swapped. Im certain its the right washer.

For the last 4 hours i've gotten nothing accomplished. Im stuck trying to get the gear rack back in the bike with all 3 shift forks. I got the gear rack back in with no.2 and no.3 shift forks but i can not for the life of me get the 1st shift fork out of the way enough to put the outer most gear on the left side (the one with the dremel'd dogs) and put the shift fork on it. No matter how far i push it up out of the way the upper prong on the fork wont slide down into the slot on the gear. The instuctions on the guide im using say to pull the 1st fork up and pull the gear with the dogs on it out. This worked for removing the gear and the first fork fell out. Why wont this work for getting it back in!?

Using this guide: http://www.xs11.com/xs11-info/tech-t...procedure.html

The removal - Option 2
This will give you free access to all of the gears on the countershaft. Sharpening the slots on second gear will be cleaner and easier, but this will be offset by more trouble in trying to get the countershaft and all the shift forks back into place during re-assembly. This option is necessary for problems with other gears.


Remove the second circlip on the shift fork shaft (Clymer's, page 126, Figure 53)
Remove the 3 Torx bolts securing the countershaft bearing housing and remove the housing. These bolts have been loctited in place so it may be difficult to remove them (Clymer's, page 126, Figure 55, Figure 56)
Remove the washer/bolt from the end of the countershaft (Clymer's, page 128, Figure 57)
Withdraw the shift fork shaft completely.
Remove the loose shift forks.
Reaching up from below with your right hand, push fifth gear out of the transmission.
Slide the countershaft assembly slightly to the left, then down on the right, and the whole works will drop out of the bottom.

You are now ready to repair the damaged gears.

The wrap-up:
When you're done, retrace your steps back to the start. (<-- load of ****)

Also i want to note that no where in these instructions does it state the oil pan and oil pump need to come out to get the gear rack out. Several links in the guide are no longer functioning and some of the information is not specific enough to determine what actually needs to be done to complete certain steps.

[James England]

FFFFFUUUUUUUUUUUUUCCCCCCCCKKKKKK!!!!!!!!!!!!!

Not necessary here, IMO .

Sounds like it was a hell of a job. It can be very frustrating. I've done 3 of these and not one single time was I able to get it back together after the washer swap. Leaving the washer in its original position, all three went back together. It could be that...

[TomB]

I had the same problem, and I think the cursing was entirely necessary

You cuss away my friend!!

However I found the cure, for my job anyway.

After removing the clutch I held a piece of soft ali on the end of the clutch shaft to protect the thread, and drifted the shaft (with gentle blows) through the bearings towards the gear lever side of the engine about 3/16" maybe even 1/4", this gave a huge amount more room to get the gear rack in and out, so once the last gear (5th) is slid back on, the shaft can still float about for the last selector to slot in easier.

The clutch shaft pulls back into place when tightening the clutch nut.

HTH

Tom



.

[strom]

We removed the engine and split the cases for the job...

Anyway, put on the shift forks the wrong way.... took a bit to figure it out, but it was late and we were tired.

I would suggest a good nights sleep and some more foul language with a beer handy to celebrate when you succeed...

[James England]

I had the same problem, and I think the cursing was entirely necessary

You cuss away my friend!!




.

I agree, but time and place. The place isn't here, surely? Definitely in the garage, workshop or actually at the bike. I think we've all been there....

[TomB]

Hahahaha, James you appear so upset at the cussing and yet you had to go quoting again

Yeah we've all been there.



.

[crazy steve]

I know exactly what the problem is, because I had the same one....

The answer is in the first pic of part three of the 'fix' (look here: http://www.xs11.com/forum/showthread.php?t=5090. Much better pics...) You can't get the gear in because the shift fork is in the way, right? It almost clears, but not quite.

Look very carefully at the pic, paying particular attention to the shift forks and drum. If the middle fork (the one you didn't have to remove) isn't 'shifted' to the left as shown, there won't be enough room to drop the right fork down between the gears. Once I realised that and corrected it, it went right together...

I'll note that I didn't do the washer swap, as after looking at how everything fit together I didn't see the point of it. You get full engagement of the dogs with it in it's 'correct' place, swapping meant the dogs stuck through the 2nd gear slots...

[Irukandji]

Originally Posted by TomB
I had the same problem, and I think the cursing was entirely necessary

You cuss away my friend!!


James England quote..
I agree, but time and place. The place isn't here, surely? Definitely in the garage, workshop or actually at the bike. I think we've all been there....


Agree, in the other XS forum.

[motoman]

First shift fork doesn't have to go in till after the gear assembly is in......then slide that last gear on the end of shaft after fork is somewhat in place.

[DGXSER]

I certainly understand the frustration level. It starts to feel like your screwed and the flippin thing will NEVER go back together again!! BTDT printed up the T-shirt!! Yep, done this thing more than a few times. Actually did it three times on my current bike alone, no where near agressive enough in my grinding first time on this one. Repeated on first, then go in again to re-fix second gear.

Every time, it is something else that gives me fits. The trick I find is to have 2nd gear shift fork in place and hold the 1-4 shift fork in place when you go to put the countershaft in place. Then get the shift fork shaft through those before you start with the 2-5 shift fork and sliding fifth gear in place.

Once you have the shaft installed, and the other two shift forks in place with the shaft through them, now put the 2-5 shift fork in place. slide it up into the engine, may have to let it lay on its side. Start sliging 5th gear in and with alot of patience work that shift fork downover the gear. Easier said than done, but it is the way it works for me.

BTW, I have never done the gear repair without swapping the washer. Never had to put the washer back to get the gear shaft back in.

[BA80]

Wouldstock, I did it the hard way like you but I got it done after a lot of wiggling, jiggling, and yes I INVENTED a few NEW words.

A friend of mine told me that he used a piece of heavy wire, like a clothes hanger, in place of the idler gear/shift fork shaft to put it together and then slid the shaft into place and it was much easier.

Just an idea.

[Wouldstalk]

First of all i want to apologize for those my cursing offended. I had a very strong urge to kick my bike over by the time i decided i was finished for the night. Instead i came on here half venting and half asking for help.

Im going to use the pictures in the link crazy steve posted along with the heavy wire through the shift fork shaft to hold the shift forks in place while i jiggilize the counter shaft into place and see if thatll help. I know it will make it in eventually. I was just frustrate with how seemingly easy getting it all out was and how ridiculously tedious it is to get together again.

6 hours for the break down, and 4 to have accomplished next to nothing on re-assembly

Thank you all for your help once again, i really do appreciate it! Ill be sure to post pics of the bike once its done too!

[DGXSER]

The first time I did this repair, I to found myself at the breaking point trying to get the countershaft back in. I spent about 4 hours breakign it down, two hours grinding gears. And then eventually, into the work week on the second evening or working on it, the stars aligned and things went back together. So I do feel your pain.

It will go bakc in, and the shift forks will eventually get into the right spots. Do note which of the outer shift forks is which, they have numbers on them. Would not be the first tiem someone got it all together only to find they had those swapped.

[Wouldstalk]

The first time I did this repair, I to found myself at the breaking point trying to get the countershaft back in. I spent about 4 hours breakign it down, two hours grinding gears. And then eventually, into the work week on the second evening or working on it, the stars aligned and things went back together. So I do feel your pain.

It will go bakc in, and the shift forks will eventually get into the right spots. Do note which of the outer shift forks is which, they have numbers on them. Would not be the first tiem someone got it all together only to find they had those swapped.

Yeah i've got the shift fork in the right order, 1 closest to the shifter paws (left side) and 3 farthest right. 2 is inverted.

The stars will align at some point, as with most things ive been fixing, some small tweak just happens to be a perfect fit for the fix. Just waiting for it as patiently as possible.

[Wouldstalk]

About 15 hours total to do this job. Going to go for a test ride tomorrow to see how it performs. Would have been just over ten hours for my first dremel fix job, if it werent for that damned shift fork!!!

Thank you all so much for the info and help.

for those wondering, i ended up sort of lodging the no.1 shift fork sideways against the gear, right over the slot and used the friction of it being jammed sideway on it by turn the gear whilst prying the fork down. It wasnt really a forceful process, just some slight pressure to keep it in place. first two attempts it sprung back out of place, resetting it each time. Third attempt with a bit more pressure and it popped into place. Not recommending this become a standard procedure, but it worked in this case without damaging anything.

Will report tomorrow with how it runs, if it goes well you all get a picture or two!