While we are on the subject of gears... Strange shifting

[motoman]

'Gap-rod' to the rescue...........in the future, if the 'dogs' jump the slots in first or second gear, that'll likely happen again........which will then lead you to the 'gear fix'.

[Orange4]

Off topic, I want to remove the aluminum cover adjacent to the starter cover to polish it. What is behind there? A bearing? Can I remove it without opening up a can of worms?

BTW, when the dogs pop out do you end up in neutral or a lower gear? Also, who let them out?

[jetmechmarty]

BTW, when the dogs pop out do you end up in neutral or a lower gear? Also, who let them out?

It will remain in the 2nd gear position. Instead of forward motion, you'll get a lot of noise as the edges of the dogs and slots are beaten into a round shape that will ensure they never engage. It will feel like a very noisy neutral.

[Orange4]

Ok. good. That has never happened under my watch. I think my 2nd gear is OK. The PO said he had second gear fixed years ago by Yamaha (insert craigslist seller disclaimer here). Although I do get clutch slippage under WOT at about 6500 rpm so I won't know for sure until I fix that and take it for a boot.

On the topic of craigslist sellers, the guy who sold me the '79 told me it had a new set of rings and it actually turned out to be true when I took apart the top end. Craigslist miracle?

[mack]

Cover

I didn't notice anyone answer your question about the the other half of the starter cover. You are correct in assuming there is a bearing under it. The bearing is fixed to the cover and will pull off with a little persuassion. There are two thin oil seal rings which make it a little tight to slide out. The end of that shaft the bearing fits on is the primary that the hyvo drives and immediatly inside the case(on that side) are the conical springs that take up the snatch when shifting into first. It's all cool to remove it and buff it up, nothing will fall out or drop down.

[donebysunday]

I was going to mention before but got sidetracked.

This is for anyone that knows and can answer. Pertaining to the condition of his star washer, something caused this, should it be investigated before riding for what really was the cause ?

Ok. good. That has never happened under my watch. I think my 2nd gear is OK. The PO said he had second gear fixed years ago by Yamaha (insert craigslist seller disclaimer here). Although I do get clutch slippage under WOT at about 6500 rpm so I won't know for sure until I fix that and take it for a boot.

On the topic of craigslist sellers, the guy who sold me the '79 told me it had a new set of rings and it actually turned out to be true when I took apart the top end. Craigslist miracle?

[Orange4]

Thanks for the info on the starter cover's neighbor. It's as good as polished.

I'm guessing the star washer was bent when it mis-shifted but whaddoiknow?

Also, no one informed me as to the situation regarding the dogs and the identity of the person or persons who allowed them to become loose.

[motoman]

I was going to mention before but got sidetracked.

This is for anyone that knows and can answer. Pertaining to the condition of his star washer, something caused this, should it be investigated before riding for what really was the cause ?

.....post #31.

[Orange4]

So are these designed to pop out to save the gears? Hence the whimpy retaining tabs?

[motoman]

So are these designed to pop out to save the gears? Hence the whimpy retaining tabs?

I think some reading is in your near future. That tab U 'fixed' has nuttin' to do with popping out of gear......that's the result.
ALOT of unwanted motion from pieces that are SUPPOSED to be LATERALLY stationary goes on to cause that......initially all started from improper shifing technique clutch adjustment AT clutch incorrect, 'speed' shifing or all of the above, whichever so slightly rounds off corners of gear engagement 'dogs'.

[anarchy18]

Why did he tackweld the tip of the washer back on are they that hard to find or expensive? Well here begins the perilous journey of translating the part names like shiftfork into German and trying to find one here I put in tranny and xs1100 in German Ebay and everythings for the 2H7 and 2H9 models will those fit in my 5K7?

http://www.ebay.de/sch/i.html?_odkw=...s1100&_sacat=0

[Orange4]

I fixed it so I could go riding instead of waiting for a new part to arrive.

I don't know if the transmissions are identical. I would think they are but I'm not an expert here. James England probably knows.

[Orange4]

Update. It now shifts much better after adjusting the eccentric as per the instructions. Especially better shifting down into first gear. It still gets stuck while downshifting between third second but much more rarely.

Thanks!

[TopCatGr58]

Hey folks,

My question is why was the shift drum assembly built that way with varying length pins necessitating that funky washer? The pins all bottom out at the other end of the shift drum, why weren't they all set to the same length, so that a simple stronger flat washer could be used to secure them in place?? IF mine ever bends/breaks, I'll probably just grind down the pins level and put a big flat washer there!

T.C.

This will have to do for now. That's a 308L 1/16" filler rod welded to the washer. I also did a bunch of little jobs that have been nagging at me like properly mounting the spaghetti pipes. Next job is to replace a few exhaust studs that have been bodged by the PO.

[anarchy18]

Heck Ya TC GOOD IDEA!!! Think I can do that with mine if my funky washer (and that really is a awkward dang washer) is bent or broke and pins fell out? What if there are no pins in my oil pan where do I get some new ones so I have my 5th gear back!!!