Interesting 2nd gear fix

[joep7]

And then the fun began. Was able to get one shift fork out but the others were locked in.

Was able to wiggle it a bit and then turn the middle drive, after some grinding and moaning it popped and finally saw the damage.





So got that gear out and the gear that it pairs with is just as bad.



That is when I noticed something...

The clip that should be holding this shaft in place is missing...there is about 1/4 play back and forth on the whole shaft.



It is part number 2 on this diagram...the big clip of course.


Could that have caused part of the issue? I wonder if it was missed or broke....

In any case. Can I get this shaft out without spliting the case?

[BA80]

No, it won't come out without splitting the cases but what does the gear that one meshes with look like?

Looks like you'll pretty much need a new tranny.

[joep7]

No, it won't come out without splitting the cases but what does the gear that one meshes with look like?

Looks like you'll pretty much need a new tranny.

Yup new tranny is the plan...Is there a way to split the case enough in the frame to ease it out? I really....Really dont want to pull the motor out.

[TopCatGr58]

Hey Joep7,

The #2 clip...that diagram BTW shows two #2's, but I think you're talking about the lower one for the PRIMARY SHAFT...that large "C" clip is actually inside the edge of the engine case....it is holding that bearing in the case, it does NOT clip to the Primary shaft. The exploded diagrams are sometimes misleading!

We would need to see the countershaft with the gears on it, but it's the shift forks that slide them in and out of engagement, and so it was most likely the shift forks that allowed the 2 gears to engage the same single primary shaft gear!!

I can't answer the question about splitting the case IN THE FRAME.....others have experience with splitting the cases....but I don't recall anyone doing it with the engine still in the frame!? However, I think all of the case bolts are accessed from the BOTTOM side of the engine...remember there are 2 hidden inside the oil filter cup chamber. They are all numbered...see your manual for their location and order of lossening and tightening.

T.C.

[BA80]

Yup new tranny is the plan...Is there a way to split the case enough in the frame to ease it out? I really....Really dont want to pull the motor out.

You need to pull the engine out. Only way to do it. It's not as difficult as it may seem,

If you have any trouble finding what you need let me know and I'll see what I can do.

[joep7]

Hey Joep7,

The #2 clip...that diagram BTW shows two #2's, but I think you're talking about the lower one for the PRIMARY SHAFT...that large "C" clip is actually inside the edge of the engine case....it is holding that bearing in the case, it does NOT clip to the Primary shaft. The exploded diagrams are sometimes misleading!

We would need to see the countershaft with the gears on it, but it's the shift forks that slide them in and out of engagement, and so it was most likely the shift forks that allowed the 2 gears to engage the same single primary shaft gear!!

I can't answer the question about splitting the case IN THE FRAME.....others have experience with splitting the cases....but I don't recall anyone doing it with the engine still in the frame!? However, I think all of the case bolts are accessed from the BOTTOM side of the engine...remember there are 2 hidden inside the oil filter cup chamber. They are all numbered...see your manual for their location and order of lossening and tightening.

T.C.

There looks to be a groove for the the clip. Should I be able to move that shaft back and forth a 1/4 of an inch?


The dogs all seem ok, the shift forks seem ok. Kinda weird. I'll get more photos.

[BA80]

Hey Joep7,


I can't answer the question about splitting the case IN THE FRAME.....others have experience with splitting the cases....but I don't recall anyone doing it with the engine still in the frame!? However, I think all of the case bolts are accessed from the BOTTOM side of the engine...remember there are 2 hidden inside the oil filter cup chamber. They are all numbered...see your manual for their location and order of lossening and tightening.

T.C.

There is no way I can see to split the cases in the frame. There are bolts in the top also.

[DGXSER]

I'm not certain there is any way to do it in the frame, but honestly, I suspect if you tried to, by the time you finished horsing around with it and trying to get the top end lifted off, you will be hating life bad enough to wish you had just pulled the engine out. JMHO

[joep7]

You need to pull the engine out. Only way to do it. It's not as difficult as it may seem,

If you have any trouble finding what you need let me know and I'll see what I can do.

Thanks for the offer. Im sure I will have questions. I pulled my cb900 fine enough....its just not something I WANT to do. But I will man up and do it.

I have completely rebuilt a 350 twin but i know that is a whole other animal.

[joep7]

If I am going to pull the motor and split it. Other than the obvious gaskets and oil parts, what are some other things I should maintain, replace, or check while its apart?

[BA80]

Refreshing the starter clutch is ALWAYS a good idea since you'll be right there. Here's a kit on fleabay http://www.ebay.com/itm/YAMAHA-XS110...-/270798038349 . There are other sources though.

[TopCatGr58]

Hey Joep7,

How many miles are on the bike?? Yes, like Greg/BA80 said the starter clutch parts are one of a few things that you can not access/repair without splitting the cases. www.partsnmore.com ...see this link for listing of parts for our machines: http://www.partsnmore.com/parts/yama...itting]=custom

The Primary Chain is another thing.....but they behave okay even when stretched a bit....just can slap against the engine case when loose and give a little more drivetrain slack feeling/jerk, but there are many other drivetrain slack points as well. The cam chain CAN be changed without splitting the case, but is more easily accessible with the cases split.

The crank /rod end and crank main bearings are getting quite hard as well as $$ to find....but folks will recommend Plastigauging them while apart to see if they are still within spec. If out of spec...and with the amount of damage to the tranny....it might then be cheaper to find a used working engine vs. trying to repair/rebuild this one??? YMMV.

Greg, I thought I had read where someone had split the cases without having to pull the jugs?? But I could be wrong.

T.C.

[BA80]

Your link doesn't work TC. I looked at Parts-n-more and didn't see the starter clutch kit.

And no. You DON'T need to pull the jugs to split the cases. I at one time thought so but was corrected..............repeatedly.

[TopCatGr58]

Thanks Greg...I fixed my post/link, it works now, and scrolling down the page to near the bottom, the starter clutch parts are there, $28.00 for the kit, rollers, pins, springs.

T.C.

[BA80]

OK, I see it now. Scrolled past it at first I guess.