Question on bottom end swap from 80 to 81 special.

[BigOates]

I bought an 81SH a few months ago and it had a bad transmission and was making a sound similar to a garbage disposal when running. It was coming from the bottom end. Anyways I've disassembled the motor and getting ready to spilt the cases to see what I can find. I'm leaning to it being transmission related as the bike would jump out of second gear above 4k and you could feel the transmission slipping in third and fourth.

I found a gentleman locally who sold me an 80 special parts bike that had a bad top end and missing a few parts. I'm planning on swapping my 81 top end onto the 80 bottom end and placing it back into my 81 frame. I was wondering if that would be a direct swap or if there we're any problems I would run into with the different years. I believe the 80 still had the mechanical advance and the 81 deleted it. So would I need to swap the tci's as well? Any other thoughts? I also am planning on getting the other motor running eventually and using as a spare.

[crazy steve]

Well, the good news is, you won't have to swap top end parts. You'll still need to fix the trans, but you don't need to split the cases to do so (contrary to what the service manual says... ).

Look here: http://www.xs11.com/forum/showthread.php?t=35964

You can do this with the motor in the frame or out, your choice...

[crazy steve]

Oops, wrong thread...... http://www.xs11.com/forum/showthread.php?t=5090

[BigOates]

Haha! Wish I would've known that! At least I've got a complete 80 engine as a backup then (said it needed rings)! I already have the engine out, top end removed, and the bottom end down to the part of removing the stator and ignition advance. When looking through the oil pan before doing taking apart, I didn't see anything obviously wrong. I'll try and get some pictures tomorrow of the transmission gears. I don't have a lot of experience with working on the transmission so I'll be asking here a bunch I'm sure. Btw, the link went to the carb identifier guide?

[crazy steve]

Btw, the link went to the carb identifier guide?

Yeah, sorry.....

[BigOates]

Well I got some pictures of the fifth gear. I'm still going to separate the cases to pull out the rest of the transmission (and I scored a full kickstart assembly for $20 on ebay). The dremel fix doesn't look too bad. I'm assuming I can get the dremel attachments at Lowes or Home Depot.

Where I am stuck at now is removing the stator. I've got the 16mm motion pro tool. It's just not pulling the stator out when I crank down on it. I've tried the pry bar and also an impact gun. Didn't budge and started making a few metal shavings so I called it a night. I've sprayed some pb blaster in the hole hoping that may free it up. Any secret tips to pulling it off?

[bikerphil]

On removing the rotor, with the bolt tight, give the rotor a smack with a hammer, hopefully it should pop loose. Sure you have the correct bolt, it should have a flat end on it going into the rotor, no kind of taper.

[BigOates]

Yeah I've got the motion pro 16mm with 1.5 pitch and flat bottom. I smacked it a few time and it didn't budge. I was out of ideas at that point!

[bikerphil]

I remember one that I had to remove long time back, I had to put a long screwdriver thru the rotor to keep it from spinning, then tighten the bolt with a breaker bar and a pipe on it for more leverage before it finally came off.

[BigOates]

I'll give that a shot tomorrow. Hopefully that stubborn bugger will give in!