Fix trans

[BA80]

OK........you lost me Don. What mystery washer?

[TopCatGr58]

Hey Greg,

See his first post and photo, but that washer looks too big diameter wise to be the one to fit on the end of the shift shaft and idler gear, as I stated it looks more like the washer for the oil filter/spring assembly!

T.C.

[BA80]

Saw it TC. That washer looks too small though.

Now that I go back through the whole thread I see what he's saying.

It probably got knocked loose when the clutch pack or the shaft bolt was removed. Does it fit on the shift fork/idler gear shaft like it belongs there? What I mean, is it the right size?

[3Phase]

Thanks for your patience, T.C.! (laughing) I hope to heck I don't have to go back into that side cover any time soon but I will be using a spare engine to suss things out before I decide what to do.

Marty,

I don't want the plate, I want to get rid of it!

I'm sure there will be a few places that still have some 2H7 Plate, Side 1s but Yamaha quite making them so eventually they'll be just as gone as the XS. I think someone recently unearthed an XS that was or is still in its factory crate....


.

[trbig]

Yeah, I forgot. There is a very thin small washer that goes between the gear and the c clip. Dig around in your pan and look for it. It may be still stuck to the side of the gear.

[bikerphil]

That larger washer, maybe someone tried to 'shim' the transmission to lessen the slop.

[donebysunday]

Yeah, I forgot. There is a very thin small washer that goes between the gear and the c clip. Dig around in your pan and look for it. It may be still stuck to the side of the gear.

That C clips is all that was in the the pan. I'll go back in this post and look at that gear again but I don't remember seeing a washer there ?
Can Ace help me out here with a washer for behind that C clip ?
Thanks You All !!!!! Done };~)

[trbig]

That C clips is all that was in the the pan. I'll go back in this post and look at that gear again but I don't remember seeing a washer there ?
Can Ace help me out here with a washer for behind that C clip ?
Thanks You All !!!!! Done };~)

That washer is pretty small and the thickness of it may be critical to keep the gear from slopping around. I was suggesting that it may still be stuck to the gear with oil suction keeping it there, but it could be in the bottom corner of your clutch cover, or tucked away under the drain bolt threads of your pan.

Not sure how critical it is exactly, but the one behind the gear against the other circlip will give you something to match up.

[Schming]

I'm back to guessing, thank you Marty !

Could not find the C clip but found this diagram of the oil pump with a washer behind the C clip on the oil pump gear drive on the end of the shift shaft ? ? ? Could be that mystery washer ?



Now what ? LOL Oh yeah #22

Hi Done, JAT, You may want to pull the gear off and compare the found washer with #22 washer on the rear face of the gear and if not the same 'least you'll have one to match a new one with.

That C clips is all that was in the the pan. I'll go back in this post and look at that gear again but I don't remember seeing a washer there ?
Can Ace help me out here with a washer for behind that C clip ?
Thanks You All !!!!! Done };~)

Also, these washers are most likely hardened and your local hardwares may not be which, if used, could lead to metal filings coursing through the galleys. HTH / GL

Ha, Todd beat me to it ;-)

[jetmechmarty]

Just let the local dealer get you the washer. It should only cost you $3.

90201-12471-00

[BA80]

Hi Done, JAT, You may want to pull the gear off and compare the found washer with #22 washer on the rear face of the gear and if not the same 'least you'll have one to match a new one with.



Also, these washers are most likely hardened and your local hardwares may not be which, if used, could lead to metal filings coursing through the galleys. HTH / GL

Ha, Todd beat me to it ;-)

No real stress on that washer. More or less just a spacer. Anything the right size should be fine but if you can find a grade 8 or 10 it would be better.

[donebysunday]

I'm back to guessing, thank you Marty !

Could not find the C clip but found this diagram of the oil pump with a washer behind the C clip on the oil pump gear drive on the end of the shift shaft ? ? ? Could be that mystery washer ?



Now what ? LOL Oh yeah #22

The second mystery washer is an exact match to the one behind the oil pump drive gear. So now I know where that second washer goes. I'm going to bevel slightly the edges on the C clip even though I see no wear on the more rounded side of that washer. Maybe the clip was never installed all the way at YAM. ?

THANK YOU ALL !!!!! Done };~)

[3Phase]

Huh?

I'm going to bevel slightly the edges on the C clip even though I see no wear on the more rounded side of that washer. Maybe the clip was never installed all the way at YAM. ?

The clip shouldn't need to be beveled.

The clip should be installed with the bevel side facing inward toward the washer and the straight side out. That should keep the clip from being squeezed out of its groove, off the end of the shaft and into the oil pan.

.

[trbig]

Exactly what 3phase said. You want a square edge, so when the gear applies pressure to that outside circlip, it doesn't just pop off again. Bevel it, and you might as well just throw that clip and washer back into your oil pan as you button everything up, since it'll be there shortly anyway.

[donebysunday]

C clip

Thank You All Very Much !
When I tried tightening this C clip by pulling the ends together I may have bent it so that the ends with the holes in them are not exactly lined up. This is why I thought of beveling these ends. I could take it back off and use my dial caliper to make sure it is straight but I see the clip is available for $1.79 at my local dealer part # 99009-12400-00 and it's used in everything from scooters to snow, and water craft. Might even have one in my XS650 parts box but a new one is the way to go I think.
Thanks Again ! Done };~)

Now I just have to wonder why that parts fiche showed 2 washers and the bolt on the end of the trans drive shaft ?