Fix trans

[donebysunday]

Hi XSives !
In all the manuals I have they only show one washer on the bolt behind the clutch basket that holds the drive axle. But OEM parts shows three. When I took out that bolt I was careful to hold onto the big washer but seconds after removing it another smaller washer fell to the floor, would appear they all go together on that bolt. Here's what I have.



Do these 3 parts belong together ? Thanks ! Done };~)

[trbig]

It appears you have all the pieces there. Not sure where you're seeing three washers at, but it's two washers and a washer headed bolt. Looking at the parts fiche, it looks like there was NO washer from 78-80, but I suspect there were several problems of that bolt backing out like I had. So, they changed it. What you have is apparently the same setup as the XJ as well, though with the several motors I've been through on my bike, it seems to me I only remember using that larger "Plate washer" though, and not the smaller one.

But yes.. if you have them there, I'd put them back adding some loc-tite to the bolt.

[cpmaynard1980]

+1 on the Loc-Tite. I found it out the hard way.

[donebysunday]

It appears you have all the pieces there. Not sure where you're seeing three washers at, but it's two washers and a washer headed bolt. Looking at the parts fiche, it looks like there was NO washer from 78-80, but I suspect there were several problems of that bolt backing out like I had. So, they changed it. What you have is apparently the same setup as the XJ as well, though with the several motors I've been through on my bike, it seems to me I only remember using that larger "Plate washer" though, and not the smaller one.

But yes.. if you have them there, I'd put them back adding some loc-tite to the bolt.

Sorry ! I meant two washers.
The manuals I have only show the larger washer, I asked Marty and he mentioned OEM parts, that's where I found the only fiche that showed 2 washers.
So because it just fell out and I was not sure where from I questioned.
By the way that bolt was not very tight took very little to get it out.

Now a couple more, first is this star retainer bent ? If so it does look like it to me, not very much though, maybe could be bent back ?



This is what I found in the pan, a C clip like what is used on the shifter shaft and pawl. Glad I pulled the pan with the bike on the center stand ! Is there another place I should be looking to put this, or just count it as a extra that happened to fall in during mfg. assembly ? Don't understand how it could come off something without breaking ?



Thanks To All ! I'm moving very slow on this fix.

[trbig]

Look at th eother side of your motor for where that clip in the pan goes. There's a rod that goes all the way through the motor that your shift forks go on, and on the clutch side, there's a small idler gear that is run from the gear on the back of the clutch basket that runs your oil pump. There should be a clip on both sides of that small gear, and the outside one has been known to fall off. The gear can't come out though because it can't get past the clutch basket, though it won't run your oil pump well and might tear up the small gear wiggling around.

[trbig]

Oh.. and the star washer.. I'd gently tap those little arms back down onto the pins.

[TopCatGr58]

Hey there Done,

I also have an 81SH that I've been into the tranny with, and I did NOT have that smaller washer!!! Just the washer/bolt combo and the narrow extra washer that fits around the groove/shoulder of the large washer head bolt. That bolt should have ~50 ft/lbs of torque!!!!

That smaller washer almost looks like the Oil Filter spring/washer!?

Tod's right about the "C" clip, probably came off the other end of the shift shaft with the oil pump idler gear.

The Shift drum washer is a conundrum to me.....the shift PAWL grabs the pins INSIDE the groove of the shift drum that the pins are sticking into, not on the outside end of the drum, so why did YAMAHA need to leave extra pin length for those 2 pins for 4th and 5th gear, and use that wimpy bent washer!? If Mine ever bends, I think I'll GRIND down the extra length of pin, and then just use a single FLAT thick washer on the end to hold it in place so I won't have to worry about those little tangs getting bent again!? Any thoughts from Crazy Steve or 3Phase, or other semi-engineers!?

T.C.

[3Phase]

T.C., Doneby,

The star washer, 2H7-18561-00-00 Plate, Side 1, is no longer available.

In Yamaha-speak 18561 seems to mean it's a Plate, Side 1, and there are a lot of Yamahas that use it with their model as the prefix. None of the ones I found would work on an XS or XJ shift drum.

After chasing that rabbit down its hole I started to figure out how to make a better washer or eliminate it entirely. I want to get rid of that goofy starfish washer and not ever have to lay my jacket on a barbwire fence along a country road 300 miles from home so I can lean the bike against it while I pull the left side cover and fish shifter pins out of the oil pan.

I got sort of involved in painting and doing the brakes and bearings and forgot about it. Sorry about that!


.

[donebysunday]

Look at th eother side of your motor for where that clip in the pan goes. There's a rod that goes all the way through the motor that your shift forks go on, and on the clutch side, there's a small idler gear that is run from the gear on the back of the clutch basket that runs your oil pump. There should be a clip on both sides of that small gear, and the outside one has been known to fall off. The gear can't come out though because it can't get past the clutch basket, though it won't run your oil pump well and might tear up the small gear wiggling around.

Good thing the gear is still good, look what I found , NO C clip on that gear, should I replace all C clips or can I use the one in the pan ? If not do I need to go to Yamastealer or can I use ACE ?
Thank You So Much ! Done };~)

[trbig]

No, you can just re-use it, but look closely at it. One side of it will have a very squared edge to it and the other side is somewhat rounded. Put it on the shaft with the more rounded side towards the gear and the square edge away from the gear facing outward. I also like to try to squeeze the clip together a few times to try to make it just a touch smaller before installing.

[jetmechmarty]

T.C., Doneby,

The star washer, 2H7-18561-00-00 Plate, Side 1, is no longer available.

In Yamaha-speak 18561 seems to mean it's a Plate, Side 1, and there are a lot of Yamahas that use it with their model as the prefix. None of the ones I found would work on an XS or XJ shift drum.

If you want that plate bad enough, Speed and Sport has it.

[James England]

I have a star washer here, if you get stuck.

[donebysunday]

Good thing the gear is still good, look what I found , NO C clip on that gear, should I replace all C clips or can I use the one in the pan ? If not do I need to go to Yamastealer or can I use ACE ?
Thank You So Much ! Done };~)

Just saved me a whole lot of guessing, Thank you so much ! I can re-use this clip !

[TopCatGr58]

Apologies for the slight thread hijack!

Hey Scott,

No problem, life happens! Since you're more likely to be going into your shift cover in the near future, I'll "LET" you play with it to see what's involved in eliminating it. It looks like to me that it would be just a matter of drilling a few extra holes near the middle where that fancy "A" shaped alignment washer fits onto the end with what looks like a couple of extra dowels, along with the original gear dowels.

Two choices looks to me...one, either use 2 washers, one drilled to allow the extra dowel lengths to stick up thru, and then another washer on the outside/top to secure them in place so that they could not be pulled/pushed outwards.

The other way would be like I mentioned, grind down the extra ends of the dowels sticking out, and then just secure a nice thick(2mm) fender or other appropriate washer over ALL of the pins..., again just drilling the extra holes for the "A" washer.

Take lots of pictures!

T.C.

T.C., Doneby,

The star washer, 2H7-18561-00-00 Plate, Side 1, is no longer available.

In Yamaha-speak 18561 seems to mean it's a Plate, Side 1, and there are a lot of Yamahas that use it with their model as the prefix. None of the ones I found would work on an XS or XJ shift drum.

After chasing that rabbit down its hole I started to figure out how to make a better washer or eliminate it entirely. I want to get rid of that goofy starfish washer and not ever have to lay my jacket on a barbwire fence along a country road 300 miles from home so I can lean the bike against it while I pull the left side cover and fish shifter pins out of the oil pan.

I got sort of involved in painting and doing the brakes and bearings and forgot about it. Sorry about that!


.

[donebysunday]

If you want that plate bad enough, Speed and Sport has it.

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