No neutral issue need help

[Itsdamadhatter]

http://s1358.photobucket.com/user/it...atter/library/

I'm having issues getting the link so here in my library I put a video up of the case open. I'm lost.

[BA80]

Separating the cases was unnecessary. Click on the pic and the video will start.

[Itsdamadhatter]

I seperated the cases because I'm being told there's gears out of place or circlips lost so I'm digging for the issue but everything looks fine.

Nuetral I can rotate the shaft all day
Any gear locks up and spins back and forth when I seperate everything spins free

[Itsdamadhatter]

No suggestions at all

[BA80]

Put the cases back together and go in from the oil pan. One thing you could check while your still there is make sure the shift forks are installed in the correct positions. They are numbered 1 - 2 - 3 from the shifter side to the clutch side. The numbers are on the side of the forks near the shaft they slide on.

[BA80]

I would also suggest you go ahead and refresh the starter clutch since you have it all apart anyway.

The repair kit is about 3/4 down this page http://www.partsnmore.com/parts/yamaha/xs1100/?filters[category]=electrical

[Itsdamadhatter]

Shift forks are good, I pulled that rod to see if it was bent, which all is good with that

I pulled both shafts and pulled the gears off to check all the clips and whatnot all is fine with those, the bearings are good

I'm almost at the point of putting it all back together and running it hard till something actually breaks

Is there a diagram anywhere of what gears lock together when shifted?

[BA80]

I'll see if I can get trbig to help you with some of the questions I can't answer off the top of my head.

[trbig]

Sorry.. the site was down for a while for me.


I'm not trying to be rude, but I'm trying to read this thing from the beginning, and I can't really understand much of what you're saying.

I've had my bike pop into gear when it was in neutral and revved it. I've learned to never do that unless the clutch handle is pulled. Check the little throwout bearings on the cover as well as that little bearing. It should be nice and smooth rolling.

From the video: The big Hyvo chain you were checking the stretch on is fine.

All your circlips are there. For some reason, that bearing only gets a half of one as well as the one going to the big gear behind that that runs your middle drive.

[trbig]

And as a warning.. I hope you have a manual for re-assembly. The torques, along with the sequence are critical.. as well as the warnings for the liquid gasket material you use around the crank bearing journals. Also, check the little rubber O-ring where the oil pump feeds the top shell.

[Itsdamadhatter]

All bearing are good, I currently have the case open with the bottom case layin there with both gear shafts in place nuetral allows me to spin the clutch shaft all the was around,,, when any gear is engaged the gear lock up and only spin slight amount. That's with no clutch installed so to my understanding these two gear shafts should spin together no matter the gear,,,, correct
And in nuetral should the middle drive gear be spinning?

[Rasputin]

I will post a video link that Mack made, does show which gear is which and such. I dont know if it will be of any use to you but here is the link.

http://www.youtube.com/watch?v=wvk9-...ature=youtu.be

[BA80]

I was just watching that vid again and noticed that the shift return spring on the engine in the vid is real close to failing.

Just an observation.......carry on.

[trbig]

Another thing to look for with shifting issues. On the shifter side, the shifter pushes/pulls against little pins on left side of the shift drum . A starfish looking cover holds these pins in place. Sometimes they can get bent or dislodged and mess with shifting. In 2nd gear, all the lines and dots shown by the red lines should line up.









If everything looks good on that side, that shift drum that the nipples on the shift forks get guided by... On the other end of it is a star looking thick washer that a spring loaded detent pin rides on. I have had one get out of place and the circlip come off.










This will cause the forks to be in the wrong place when it's clicked into that detent spot and will cause gears meshing wrong.. neutral not being where it's supposed to etc...

[Itsdamadhatter]

Don't know how but now I have the shafts spinning free in nuetral and third gear

On the upper shaft where shift fork 2 goes on that gear which is two actually are the teeth on those even or slight offset