Won't shift into third when cold????

[donebysunday]

Maybe slight but feels fine, like it should but again there might be a slight difference ?
Only did one with the forums help and of course don't know what it felt like before as I bought it with second gear machine gunning just to see how the washer and dog clean up was done.
If your stock gearing on a special (16" rear) I am so careful with warming and putting in gear. I start once on the road from a stop in 2nd gear, really does not need any real clutch slipping, seems fine to me. Even if, clutch is easier to fix than gears ! Now if I want to burn rubber 1st gear is great but I can pull away from traffic in second just fine.

I'm encouraged by the info from Don'e and Phil.

Question: Does second gear shift feel any different after the washer swap?

[jetmechmarty]

I'm encouraged by the info from Don'e and Phil.

Question: Does second gear shift feel any different after the washer swap?

Mine might be easier to get into neutral between 3rd and 4th than it used to be. Then again, I may be imagining it. The transmission is better after the swap.

[Radioguylogs]

Trouble Reassembling Countershaft

Started reassembly of the countershaft.

Second gear is quite tight with the washer swapped, but it does spin with a little force. Frequently, the snap ring moves with the gear. Same situation as Mack's thread:

http://www.xs11.com/forum/showthread...highlight=gear

So I accept the advice it is OK to put it back together in the tight condition.

BUT...then I find the new 5th gear does not slide over the shaft splines. I forced it on with a hammer and pried it off. The witness marks indicate the bigger diameter of the shaft splines is interfering inside the gear...mostly on the outboard side of the gear.

I could wet sand the splines on the shaft and make them smaller...bastardizing the shaft, or I could try to remove the material inside the gear. The best way I can think of is to find a thin whetstone and open up the slots in the gear manually.

Unless I hear a better idea, I'll start looking for the whetstone.

[BA80]

Don't fret about it. It'll be fine 5 miles down the road.

I don't think the problem with 5th is good though. Not sure what to say there.

Work it a little and see if it frees up.

[BA80]

I think my opinion will be work on the new gear. That's where the difference is.

[Radioguylogs]

5th gear requires a hammer to install it now.

Something has to be done- clean up the old one or open up the spline slots inside the new one.

I really want to use the new one, and now there is a 2/2 consensus to work on the gear instead of the shaft (thanks for your input Greg).

Holidays are winding down, so maybe tomorrow I'll have a chance to start removing material inside 5th gear.

[tarzan]

I know Greg prefers to install the swapped washer and wear it in like that.i know several guys here do it like that. But I have done a couple of these too, and I prefer to grind a small chamfer on the inside edge of the washer so it goes up flat against the shoulder. Then everything fits perfectly upon reassembly. The problem you have is that the gear has a radius on the inside edge so when it is installed at the factory it fits properly. The shaft has a small radius there in the corner, so when you swap the washer, you end up with a square corner up against the radius. If you do grind a little chamfer on that inside edge and install the washer with the chamfer towards the shoulder on the shaft, the gear and washer will fit so that you can spin them freely.

[Radioguylogs]

Tarzan:

I recall reading that approach in another post-it must have been you.

Thanks for reminding me.

[Radioguylogs]

Yeah!

Tried a few unsuccessful approaches to the tight 5th gear spline.

The successful approach was a replacement honing stone for a brake cylinder hone. Took about 500 strokes x 7 splines, with oil. Didn't take very long.

Got the countershaft and shift forks installed in the bike, then checked the reference materials before Lock-Tite. Oops, the washer between 1st and 4th gears goes on the 1st gear side of the CirClip. (you fool Mike....I thought to check the diagram as I assembling the countershaft, but I said, "no, it seems obvious. WRONG!)

So, now I have more practice with the surgery of removing and re-installing the countershaft.

Got the bottom buttoned up, and got her back on her feet. Put in the clutch and the shift linkage, and both covers.

Now I'm getting excited

[MaximPhil]

Hi Mike,
Well done you are making progress.
Just in time to get snowed in
Phil

[Radioguylogs]

Yup

Thanks for the encouragement Phil.

Just in time to get snowed in
Phil

By the end of the week I'll be all dressed and nowhere to go!

[motoman]

Thanks for the encouragement Phil.



By the end of the week I'll be all dressed and nowhere to go!

Don't feel left out.........finially happened here last nite with a couple inches.....mostly melted, but made it colder daytime temps.

[Radioguylogs]

It going to be 17 tonight and a high of 24 tomorrow.

But I just now got everything completely finished and the oily finger prints polished off of it.

I have to try it out tomorrow. At least for few miles.

I'll report the result.

[Radioguylogs]

Shifts into Third when it's REALLY cold

Went for trial ride today despite the temperature in the low 20's.

Started right up (heated garage). No gas or oil came out. That's always a good thing.

The first 5 miles seems OK, the transmission shifted into all the gears (whew!); although it seemed 'stiff' -it took a bit more effort than I expected.

After 5 miles, it would not shift correctly. Then a truck pulled up behind me in the rural 55 mile speed zone as I was searching for a gear to get me out of the way. Wouldn't go up. I lost my place in the shift pattern. Pushed down and suddenly it ground into first gear or second gear. The back tire locked up I had a brief period of excitement. Got back off the road and found the clutch cable had stretched and settled into place, requiring it to be tightened. I really felt bad about grinding the fresh dogs

Kept riding for a while, then wouldn't shift right again. The rubber boot on the clutch lever wandered down the clutch lever and prevented it from going all the way in. I couldn't notice with my thick gloves.

Finally got back to a reliable shifting situation, and enjoyed the thrill of having it work correctly for the first time since I have owned it.

I do have one remaining issue. It's really easy to 'miss' 4th gear when I get on it and race through the gears. I think Phil has the same experience after the second gear washer swap:

Mine might be easier to get into neutral between 3rd and 4th than it used to be. Then again, I may be imagining it. The transmission is better after the swap.

I think I just have to get used to the feel.

Anyway, I'll try it again as soon as I can to confirm everything is working correctly. Maybe tomorrow?

In the meantime, I am so grateful to the forum to help me recover from my difficult situation, so I think it's time to say "Thank-you" and make another donation to the forum.

[...Bless me TC, it has been one year since my last donation].

Situation last Saturday:



Then late Monday night:

[Radioguylogs]

Oops

Marty, not Phil on the 4th gear remark.