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Thanks for the dialog guys. I should have been smart enough to realize the mysterious washer and circlip were from the OTHER side of the oil pump gear as several of you pointed out. TC's comments about the tech tip not saying to drop the pan before flipping the bike (as Greg suggests) got me thinking that maybe I should defend him too. He was correct in saying that the big stuff would be trapped against the oil pump pickup screen, even the washer from the pump gear was stuck to it. And the small stuff is glued to the pan, including that circlip that was stuck to the pan. Looking around up inside the motor with a light didn't reveal any junk that I could see. But Greg's way makes sense, you gotta take the pan off to do the repair so why not be safe and do it before flipping the bike.
Mack thank you for doing some partial assembly and taking photos. But I think the pic may be misleading (somebody correct me if I'm wrong). Are 5th and 2nd gears sandwiched together tightly in the pic as it appears that the dog is almost completely through the slot? I'm thinking that when everything is assembled completely the shift drum and shift fork don't allow that much engagement, or what would be the point of doing the washer swap? Here is another pic of my 5th gear and the visible wear is considerably less than halfway down the dog --
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Interesting to read about the various trials people have had on the reinstall. I did this fix on my own XJ 3 yrs ago, including the washer swap. There were no issues like Mack had running through the gears. In fact, as I had the motor out of the bike at the time and upside down on a bench, I ran through the gears a number of times just so I could watch what happens inside while shifting. I do recall it was an ordeal to get the shaft back in but finally managed it w/o doing the grinding that Done mentions (might come in handy this time though!)
I'm surprised the tranny doesn't have 1st gear issues as well. Look at another pic of 1st gear...that combined with the wear on the shift fork certainly point to issues don't they?
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And I remember from the last time that 1st gear is the hardest one to grind, the others aren't bad. I plan on selling the bike in the spring and don't want to have the transmission go out on the next owner soon after buying it. So I guess my options are 1) grind away, 2) buy a new 1st gear for a little over $100, or 3) have Andreas set me up with a good used tranny. Got some good advice already, just gotta decide which route to take.
Mack thank you for doing some partial assembly and taking photos. But I think the pic may be misleading (somebody correct me if I'm wrong). Are 5th and 2nd gears sandwiched together tightly in the pic as it appears that the dog is almost completely through the slot? I'm thinking that when everything is assembled completely the shift drum and shift fork don't allow that much engagement, or what would be the point of doing the washer swap? Here is another pic of my 5th gear and the visible wear is considerably less than halfway down the dog --
[IMG]
[/IMG]Interesting to read about the various trials people have had on the reinstall. I did this fix on my own XJ 3 yrs ago, including the washer swap. There were no issues like Mack had running through the gears. In fact, as I had the motor out of the bike at the time and upside down on a bench, I ran through the gears a number of times just so I could watch what happens inside while shifting. I do recall it was an ordeal to get the shaft back in but finally managed it w/o doing the grinding that Done mentions (might come in handy this time though!)
I'm surprised the tranny doesn't have 1st gear issues as well. Look at another pic of 1st gear...that combined with the wear on the shift fork certainly point to issues don't they?
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[/IMG]And I remember from the last time that 1st gear is the hardest one to grind, the others aren't bad. I plan on selling the bike in the spring and don't want to have the transmission go out on the next owner soon after buying it. So I guess my options are 1) grind away, 2) buy a new 1st gear for a little over $100, or 3) have Andreas set me up with a good used tranny. Got some good advice already, just gotta decide which route to take.
I'd really like another but its prolly not likely to happen....
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