Interesting 2nd gear fix

[joep7]

Hello all,

Recently picked up a really nice running and looking 79 xs11 standard. Owned a special years ago and loved it. Finally tracked down a standard. Got it cheap bc of a botched 2nd gear fix. Guy sent the counter out to have the dogs cut and either jacked up installing it or it wasn't the problem bc after a few rides he said the clutch felt loose so he tightened it. Half way down the road he heard a pop and the rear wheel locked up doing 35. Was never able to get the bike out of 2nd or 3rd gear. In the stack of parts he gave me I found the shipping container that the counter came back in and there was a washer taped to the bag. Called the guy and he said oh yeah that came back with it but no diagram showed it going in the bike. Found that odd.


That's the story he tells me. Got it on the lift, final drive is fine, clutch seems fine. Won't release out of gear and I am having trouble getting the counter shaft out. I pulled the pan, left and ride side, clutch, etc and it is jammed in there good.

I will keep reading on here in the meantime but if someone has had this happen please feel free to give me some pointers to check out.

I will fill out my bio and such. Thanks for any help in advance.

[BA80]

Some pictures would help a lot.

I would suggest pulling the clutch off and taking a look. There is a bolt back behind there in the end of that gear shaft that, if not tightened properly and I use Loctite on the threads also, will come loose and be eaten by the clutch.

That extra washer is going to most likely be a factor also.

Just tossing out some ideas from mine and others experience.

[joep7]

I will get some photos. Clutch is off. Having trouble seeing up inside the transmission from any angle, be it the side or up from oil pan.

I will check on the the clutch again. And diagrams to find that washer.

[motoman]

Some pictures would help a lot.

I would suggest pulling the clutch off and taking a look. There is a bolt back behind there in the end of that gear shaft that, if not tightened properly and I use Loctite on the threads also, will come loose and be eaten by the clutch.

That extra washer is going to most likely be a factor also.

Just tossing out some ideas from mine and others experience.

+1..............cringe comes to mind............Hmmmm, washer in bag from lower shaft assembly...maybe didn't make the 'swap' and was deleted......yikes!, that could of been REAL ugly for the rider!

[TopCatGr58]

Hey there Joep7,

Have you seen the 1st/2nd gear dremel fix thread?? Yes, it's hard to look into the engine while it's still right side up! Now that you have lots of the parts off of the bike/engine, it'll be even lighter and should be a bit easier to flip over! I highly recommend it for working on these trannys. Sounds like he may have gotten the shift forks mixed up, but also could have been that the washer swap wasn't done correctly....like the guy doing the Dremel work didn't put it back on the counter shaft, so that 2 gears engaged with the primary shaft gears at the same time=lockup!

You say the final drive is fine...but what about the middle gear drive??

Yes, photos would be helpful, but can be hard to do/get from under the bike, hint, hint!

T.C.

[BA80]

Hey there Joep7,

should be a bit easier to flip over! I highly recommend it for working on these trannys.
T.C.

+1 TC. Drain all the oil from the middle and final drives first otherwise it will leak out the vents when it's upside down.

The tranny is MUCH easier to deal with with the bike on it's back.

[joep7]

Here are some photos...











If I Pull the front end off and the tank. What is the best way to flip this beast?

[bikerphil]

You have to pull that left bearing housing off and remove the shift fork and 5th gear (one furthest to the left) before the countershaft will come out.

[BA80]

Pull the tank but leave the handle bars. That'll keep it upright.

Take the mirrors off and anything else that could be damaged and balance it on the bars and the grab bar.

Get some help to turn it over.

That bolt in the bottom middle in the 3rd pic is the one I was speaking of so that's not the problem. That DOES have to be removed to get that gear shaft out though.

[joep7]

Hey there Joep7,

Have you seen the 1st/2nd gear dremel fix thread?? Yes, it's hard to look into the engine while it's still right side up! Now that you have lots of the parts off of the bike/engine, it'll be even lighter and should be a bit easier to flip over! I highly recommend it for working on these trannys. Sounds like he may have gotten the shift forks mixed up, but also could have been that the washer swap wasn't done correctly....like the guy doing the Dremel work didn't put it back on the counter shaft, so that 2 gears engaged with the primary shaft gears at the same time=lockup!

You say the final drive is fine...but what about the middle gear drive??

Yes, photos would be helpful, but can be hard to do/get from under the bike, hint, hint!

T.C.

I did read this thread. It was very helpful. I am having trouble getting the fifth gear off actually :/

[joep7]

You have to pull that left bearing housing off and remove the shift fork and 5th gear (one furthest to the left) before the countershaft will come out.

The bearing house seems fixed fast, I dont want to pry it. Should it come off that hard?

[BA80]

You have to pull that left bearing housing off and remove the shift fork and 5th gear (one furthest to the left) before the countershaft will come out.

Except for dealing with that detent for the shift drum it's MUCH easier to take the drum out getting the shaft out and back in.

But that's just me.

[joep7]

Pull the tank but leave the handle bars. That'll keep it upright.

Take the mirrors off and anything else that could be damaged and balance it on the bars and the grab bar.

Get some help to turn it over.

That bolt in the bottom middle in the 3rd pic is the one I was speaking of so that's not the problem. That DOES have to be removed to get that gear shaft out though.

I will try that in the morning. Thanks for the quick responses. This place has been very helpful and welcoming.

[joep7]

Ps.

Bought it as is with a 4 into 1 exhaust and cheap emgo pods.

Do these things run as bad as 70's and 80's hondas without the stock airbox?

It came with the stock box and I plan on putting it back on but just wondered.

[bikerphil]

That bearing housing can be carefully pried off, go evenly around each side, it is a tight fit.

Greg, I never have had to take that shift drum out or flip the bike over to service the trans. gears.