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  • #16
    Those dogs/slots look slightly rounded off and may cause a problem, I would also grind them, JMHO
    2H7 (79) owned since '89
    3H3 owned since '06

    "If it ain't broke, modify it"

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    • #17
      Back cut them so they will pull themselves together, a dovetail like the others.

      I don't know why they didn't do 1st and 2nd like the others in the first place.
      Greg

      Everybody is a genius. But if you judge a fish by its ability to climb a tree, it will live its whole life believing that it is stupid.”

      ― Albert Einstein

      80 SG Ol' Okie;79 engine & carbs w/pods, 45 pilots, 140 mains, Custom Mac 4 into 2 exhaust, ACCT,XS850 final drive,110/90/19 front tire,TKat fork brace, XS750 140 MPH speedometer, Vetter IV fairing, aftermarket hard bags and trunk, LG high back seat, XJ rear shocks.

      The list changes.

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      • #18
        I started out grinding the old gears,thinking I would reuse them and save the good ones I have for the spare motor , since it is in good shape. I spent about two hours on them before I decided to touch up the good ones and use them.lol
        I had to grind about .05 off the bad ones and I didn't like the way they were turning out.
        I just ground a few thousandths from the new ones. I only did 2nd gear. 1st looks like new. I also measured 1st and it has a back taper already.I thought that was strange, but all three dogs were that way.And they have never been ground on.
        80 SG XS1100
        14 Victory Cross Country

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        • #19
          Yamaha

          Could be some got it and some did not ? I found a set of carbs that one idle mix screw was not threaded as far down as the other.

          Originally posted by tarzan View Post
          I started out grinding the old gears,thinking I would reuse them and save the good ones I have for the spare motor , since it is in good shape. I spent about two hours on them before I decided to touch up the good ones and use them.lol
          I had to grind about .05 off the bad ones and I didn't like the way they were turning out.
          I just ground a few thousandths from the new ones. I only did 2nd gear. 1st looks like new. I also measured 1st and it has a back taper already.I thought that was strange, but all three dogs were that way.And they have never been ground on.
          76 XS650 C ROADSTER
          80 XS650 G Special II
          https://ibb.co/album/icbGgF
          80 XS 1100 SG
          81 XS 1100LH/SH DARKHORSE
          https://tinyurl.com/k6nzvtw
          AKA; Don'e, UD, Unca Don'e

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          • #20
            Originally posted by donebysunday View Post
            Could be some got it and some did not ? I found a set of carbs that one idle mix screw was not threaded as far down as the other.
            That is strange.You could always tap it deeper if neededthough.

            Have you started on you're transmission yet?
            80 SG XS1100
            14 Victory Cross Country

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            • #21
              In the Addendum that TRBIG has in the transmission repair threads, Jerry had a pictorial of adding a counter-bore to the 2nd gear. That way you can add an additional washer to it, so you will still have a washer between the gear and the cir-clip, as well as the new washer that goes behind the gear.
              So I machined a counter-bore into the gear and am adding that washer. I don't like the idea of the gear running up against a cir-clip. I know there are lots doing it that way, but this makes me feel better.



              80 SG XS1100
              14 Victory Cross Country

              Comment


              • #22
                Originally posted by tarzan View Post
                In the Addendum that TRBIG has in the transmission repair threads, Jerry had a pictorial of adding a counter-bore to the 2nd gear. That way you can add an additional washer to it, so you will still have a washer between the gear and the cir-clip, as well as the new washer that goes behind the gear.
                So I machined a counter-bore into the gear and am adding that washer. I don't like the idea of the gear running up against a cir-clip. I know there are lots doing it that way, but this makes me feel better.




                Whatever floats your boat, but it's really an unneeded step. I've got over 100k miles running against that clip, most of them pretty hard miles, and last I saw in there, there was virtually no wear on the clip. It hadn't even rubbed the color off of the surface of it (The clip). There's good oil bathing to those gears, so in theory, they should never rub together. The poor old motor is getting tired though.. maybe about time for the next motor. I'll need to check compression, but it's smoking a bit on startup now. I'll make sure to take some pics of that gear/circlip when I tear it down next time.

                If you do this counter-bore, just make sure you mount the bored side towards 5th gear or you'll be moving the gear away from 5th.. total opposite of what the whole washer move is for.
                Try your hardest to be the kind of person your dog thinks you are.

                You can live to be 100, as long as you give up everything that would make you want to live to be 100!

                Current bikes:
                '06 Suzuki DR650
                *'82 XJ1100 with the 1179 kit. "Mad Maxim"
                '82 XJ1100 Completely stock fixer-upper
                '82 XJ1100 Bagger fixer-upper
                '82 XJ1100 Motor/frame and lots of boxes of parts
                '82 XJ1100 Parts bike
                '81 XS1100 Special
                '81 YZ250
                '80 XS850 Special
                '80 XR100
                *Crashed/Totalled, still own

                Comment


                • #23
                  Originally posted by tarzan View Post
                  In the Addendum that TRBIG has in the transmission repair threads, Jerry had a pictorial of adding a counter-bore to the 2nd gear. That way you can add an additional washer to it, so you will still have a washer between the gear and the cir-clip, as well as the new washer that goes behind the gear.
                  So I machined a counter-bore into the gear and am adding that washer. I don't like the idea of the gear running up against a cir-clip. I know there are lots doing it that way, but this makes me feel better.
                  How hard was the metal at the counter bore? I thought the gear was hardened, or was that just a case harden of the tooth face? Did you use tool steel or carbide cutter/s?
                  Nice job.

                  CZ

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                  • #24
                    It seems like it is around 50-60 Rockwell.Probably closer to 50. I used carbide to cut it. The whole gear is hardened. And yes, I think it is case hardened. I'm not sure how deep. I didn't get past the hardened part.
                    80 SG XS1100
                    14 Victory Cross Country

                    Comment


                    • #25
                      Originally posted by tarzan View Post
                      It seems like it is around 50-60 Rockwell.Probably closer to 50. I used carbide to cut it. The whole gear is hardened. And yes, I think it is case hardened. I'm not sure how deep. I didn't get past the hardened part.
                      Thanks for the insight. Could a surface grinder be used to thin the washer, and get away from machining the gear?

                      CZ

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                      • #26
                        You wouldn't gain anything by grinding a washer.By adding a washer behind 2nd gear, you either have to just run with the cir-clip only, or make clearance on the gear to make room for the extra washer.
                        After reading Tod's post, I probably should have just moved the washer and not add the extra washer.
                        BTW, anyone wanting to know the thickness of the washers.They are .04 wide.

                        In reassembling my tranny, I am leaving out the kickstart gear.It makes countershaft installation somewhat easier. It also has been in there for 30 years for no reason, As this thing doesn't have the kickstart or the or the rest of the goodies nesseccary to use it anyway.
                        80 SG XS1100
                        14 Victory Cross Country

                        Comment


                        • #27
                          Circlips without washers? T'ain't natural! Needs killin'!

                          I had the 2nd gear hub cut for two washers and it works fine but I agree with Tod and a bunch of other folks that have done the washer swap -- it didn't actually need to be done! In this particular instance it's a solution in search of a problem.

                          And, yes, the 2nd gear hub is hard. H.A.R.D. Hard. It could probably be used to sharpen cutting tools but I just don't trust circlips without washers so the next time I'll have hub ground instead of cut.
                          -- Scott
                          _____

                          2004 ST1300A: No name... yet
                          1982 XJ1100J: "Baby" SS Brakes, '850 FD, ACCT
                          1980 XS1100G: "Columbo" SS Brakes, '850 FD, ACCT
                          1979 XS1100SF: "Bush" W.I.P.
                          1979 XS1100F: parts
                          2018 Heritage Softail Classic 117 FLHCS SE: "Nanuk" It's DEAD, it's not just resting. It is an EX cycle.

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                          • #28
                            Uhh huhhuh.. huh huhhuh... He said, "Taint.."
                            Try your hardest to be the kind of person your dog thinks you are.

                            You can live to be 100, as long as you give up everything that would make you want to live to be 100!

                            Current bikes:
                            '06 Suzuki DR650
                            *'82 XJ1100 with the 1179 kit. "Mad Maxim"
                            '82 XJ1100 Completely stock fixer-upper
                            '82 XJ1100 Bagger fixer-upper
                            '82 XJ1100 Motor/frame and lots of boxes of parts
                            '82 XJ1100 Parts bike
                            '81 XS1100 Special
                            '81 YZ250
                            '80 XS850 Special
                            '80 XR100
                            *Crashed/Totalled, still own

                            Comment


                            • #29
                              Tod, git yer mind out'a the tranmisison and let... I mean, you just ain't right, man!
                              -- Scott
                              _____

                              2004 ST1300A: No name... yet
                              1982 XJ1100J: "Baby" SS Brakes, '850 FD, ACCT
                              1980 XS1100G: "Columbo" SS Brakes, '850 FD, ACCT
                              1979 XS1100SF: "Bush" W.I.P.
                              1979 XS1100F: parts
                              2018 Heritage Softail Classic 117 FLHCS SE: "Nanuk" It's DEAD, it's not just resting. It is an EX cycle.

                              Comment


                              • #30
                                I am ready to install the countershaft bolt. But, the shaft is not protruding through the bearing. Should it be? The bolt has the washer.And it seems as though the washer should fit at least partially over the shaft before installing the bolt. As it is, if I try to install the bolt, the washer has to be held centered, or it will fall between the bolt head and the end of the shaft.I have pushed the shaft as far through, by hand, that I can. Should it be farther through?



                                80 SG XS1100
                                14 Victory Cross Country

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