Cant shift into 2nd while accelerating

[Rasputin]

There are pics in this link of how badly worn my gears were. The shift fork on mine was also ruined by abuse from the PO.
http://www.xs11.com/forum/showthread.php?t=31895

[Fearthepack]

Its so much easier attempting this fix knowing it will lead to the cure! First road bike is trying to scare me into just letting it sit against the garage wall forever. Thanks again and the pics link helps alot. A failure is someone who will never try.

[bikerphil]

It is not that difficult if you know how to wrench a bit. Total novices have done this fix, just take your time and ask questions if you get stuck. You will have an awesome bike after the repair. Good luck!

[Fearthepack]

One last thing. In the video link the bike is on its center stand and back wheel is spinning as you are trying to shift into second and you get the grinding not engaging sound. My bike is on side stand back wheel not moving. At idle i can get into 2nd but as i increase rpms up to 1000-1500 (rear wheel still not moving) grinding noise just like the video. Conclusion is my 2nd gear damage so bad it will make the top 5 list? All other gears fine during road test even downshift into second gear.

[crazy steve]

This pic of Rasputin's shows the damge as installed in the bike...



This is what you'll see with the bike in neutral and the oil pan off. If the bike is still upright, this will be tough to see. His aren't that bad looking, but any rounding on one side is bad; the one in my XJ was far worse than this one. Typically the damage will only be on the drive side as shown; the coast side rarely gets worn, which is why you can downshift into second but not upshift.

If you follow the directions in the 'fix', this isn't that tough. Make sure the gearbox is in 4th gear, because if it isn't you won't be able to get the shift forks back in; DAMHIKIJK...

An impact wrench if available will make getting the clutch basket nut and countershaft bolt off waaay easier...

[Fearthepack]

Nice explanation. I fully get it now! I take it this gear can no longer be purchased, and is there ever a case that 2nd is so far gone dremel fix wont work.

[crazy steve]

No, you can still buy replacements (and they're redesigned to eliminate this problem) but they're about $100 each....

As to how 'far gone' they can get, as long as one of the dogs isn't missing they can be redone at least once; twice might be pushing it...

[crazy steve]

It should be mentioned (again) that if you or the PO tried holding it in second gear by putting pressure on the shifter, you may have damaged the shift fork and gear beyond repair. If the fork fits sloppily side-to-side in the groove and looks badly worn, you may need new or different parts...