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  • #31
    Others have said that they don't have to but I always found it much easier to R&R the gears with the shift drum removed.

    The only problem with that is it takes some pretty strong cuss words to get the detent back in. It's easier with the bike flipped but it's a real PITA otherwise.
    Greg

    Everybody is a genius. But if you judge a fish by its ability to climb a tree, it will live its whole life believing that it is stupid.”

    ― Albert Einstein

    80 SG Ol' Okie;79 engine & carbs w/pods, 45 pilots, 140 mains, Custom Mac 4 into 2 exhaust, ACCT,XS850 final drive,110/90/19 front tire,TKat fork brace, XS750 140 MPH speedometer, Vetter IV fairing, aftermarket hard bags and trunk, LG high back seat, XJ rear shocks.

    The list changes.

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    • #32
      Transmission

      I have a good transmission already out. If your interested, let me know.
      1979 XS1100SF with a Jardine 4 into 1, ZRX 1200 carbs, 82 XJ rear air shocks, ACCT
      SOLD - 1980 XS1100SG with a Mac 4 into 1, ZRX 1200 carbs, round 160 speedo, 82 XJ rear air shocks, ACCT

      Comment

      • #33
        Originally posted by vanimal5k View Post
        I have a good transmission already out. If your interested, let me know.
        Thanx, but I'm not trying to turn a "leave the motor in" job into a "dismantle every piece" job...
        >>Insert clever statement here<<

        Comment

        • #34
          I thought I had posted the addendum about the easier way of putting the gear assembly back into the engine. As for getting it out, did you make sure you had the bike shifted into 4th gear before disassembly??? Once you've gotten the 5th gear wheel out/off, the gear assembly countershaft usually is allowed to wobble enough to get the other end out of the bearing, wiggling them abit, sometime rocking the rear wheel back and forth to jostle the gears a bit. Wiggling them a bit can allow the large 4th gear and idler gear to come off of the shoulder bearing on the countershaft which can also help get the assembly out.

          T.C.
          T. C. Gresham
          81SH "Godzilla" . . .1179cc super-rat.
          79SF "The Teacher" . . .basket case!
          History shows again and again,
          How nature points out the folly of men!

          Comment

          • #35
            I think I see where I went wrong...

            I was just reading back over the instructions, and I think I missed a pretty important step... I removed everything BUT the counter shaft bolt (DUH) HOW'D I miss that!? I'm pretty sure that's why it didn't come out. I even reassembled the clutch just to make sure it was in 4th gear... Smh. Anywho, I'll get it out this weekend. As far as only seeing 2 shift forks instead of 3, I guess that's something I'll figure out after I get the gears out.
            >>Insert clever statement here<<

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            • #36
              Progress?

              So this is where I'm at with my gears...






              They FEEL like they will hold, but what are your opinions from looking at them?
              >>Insert clever statement here<<

              Comment

              • #37
                Hey there,

                The undercutting ANGLE looks a little too steep, but they will wear with use. Just be aware that it will be a little more difficult to shift OUT of first gear especially if you don't use the clutch as well as letting off of the throttle for an instant, then as they wear in, it will release easier.

                But it looks like you used a LARGE grinding stone for the solid 4th gear lands instead of a smaller stone to allow you to get a bit wider zone across the land both angled/undercut as well as flatter across the width of the land because the smaller diameter stone will allow you to get farther into the corners of the solid gear.

                The 5th gear dogs also look a bit steep, but also hard to tell from the photos if you kept the round profile that fits against/into the 2nd gear curved slots?

                T.C.
                T. C. Gresham
                81SH "Godzilla" . . .1179cc super-rat.
                79SF "The Teacher" . . .basket case!
                History shows again and again,
                How nature points out the folly of men!

                Comment

                • #38
                  Originally posted by TopCatGr58 View Post
                  Hey there,

                  The undercutting ANGLE looks a little too steep, but they will wear with use. Just be aware that it will be a little more difficult to shift OUT of first gear especially if you don't use the clutch as well as letting off of the throttle for an instant, then as they wear in, it will release easier.

                  But it looks like you used a LARGE grinding stone for the solid 4th gear lands instead of a smaller stone to allow you to get a bit wider zone across the land both angled/undercut as well as flatter across the width of the land because the smaller diameter stone will allow you to get farther into the corners of the solid gear.

                  The 5th gear dogs also look a bit steep, but also hard to tell from the photos if you kept the round profile that fits against/into the 2nd gear curved slots?

                  T.C.
                  Actually, I did use a smaller stone, I just think I got a little carried away with it... And on the 5th gear, I did try to cut the inside of the corresponding gear to match. I'm gonna go over them again to do some touching up, and try to get into the corners a little better...
                  >>Insert clever statement here<<

                  Comment

                  • #39
                    Wow... Just my 2 cents here, but you took all the meat and strength out of the dogs on 5th and never addressed the actual problem. The dogs don't engage into the slots on 2nd very far. This gear here had started to slip.. and this is a picture of it as I was slowly working my way into the dog.



                    That's why we talk about moving the washer from one side of 2nd to the other. It basically doubles the amount of gear engagement. What you're trying to do with this is basically square back up the face of the dogs/lands with a slight bevel to help them stay together. So what you've done is take out the base of the dogs and left the rounded top.. the part that is making your gears skip... alone. Even without the cutting you've done, I don't think I've ever seen a set of dogs so rounded at the top.
                    Try your hardest to be the kind of person your dog thinks you are.

                    You can live to be 100, as long as you give up everything that would make you want to live to be 100!

                    Current bikes:
                    '06 Suzuki DR650
                    *'82 XJ1100 with the 1179 kit. "Mad Maxim"
                    '82 XJ1100 Completely stock fixer-upper
                    '82 XJ1100 Bagger fixer-upper
                    '82 XJ1100 Motor/frame and lots of boxes of parts
                    '82 XJ1100 Parts bike
                    '81 XS1100 Special
                    '81 YZ250
                    '80 XS850 Special
                    '80 XR100
                    *Crashed/Totalled, still own

                    Comment

                    • #40
                      Originally posted by trbig View Post
                      Wow... Just my 2 cents here, but you took all the meat and strength out of the dogs on 5th and never addressed the actual problem. The dogs don't engage into the slots on 2nd very far. This gear here had started to slip.. and this is a picture of it as I was slowly working my way into the dog.



                      That's why we talk about moving the washer from one side of 2nd to the other. It basically doubles the amount of gear engagement. What you're trying to do with this is basically square back up the face of the dogs/lands with a slight bevel to help them stay together. So what you've done is take out the base of the dogs and left the rounded top.. the part that is making your gears skip... alone. Even without the cutting you've done, I don't think I've ever seen a set of dogs so rounded at the top.
                      Your last sentence Tod was exactly my thoughts!.
                      81H Venturer1100 "The Bentley" (on steroids) 97 Yamaha YZ250(age reducer) 92 Honda ST1100 "Twisty"(touring rocket) Age is relative to the number of seconds counted 'airing' out an 85ft. table-top.

                      Comment

                      • #41
                        Although I haven't done the back-grind, I would think that it must be done such that dog/slots must all make contact when engaged, and even contact along each dog/slot contact.
                        Skids (Sid Hansen)

                        Down to one 1978 E. Stock air box with K&N filter, 81H pipes and carbs, 8500 feet elevation.

                        Comment

                        • #42
                          That was my thought the first time too skids, however, after the first engagement the dogs will become worn to do just that.

                          That being said, at least TRY to get them close to the same.
                          Greg

                          Everybody is a genius. But if you judge a fish by its ability to climb a tree, it will live its whole life believing that it is stupid.”

                          ― Albert Einstein

                          80 SG Ol' Okie;79 engine & carbs w/pods, 45 pilots, 140 mains, Custom Mac 4 into 2 exhaust, ACCT,XS850 final drive,110/90/19 front tire,TKat fork brace, XS750 140 MPH speedometer, Vetter IV fairing, aftermarket hard bags and trunk, LG high back seat, XJ rear shocks.

                          The list changes.

                          Comment

                          • #43
                            Ready to dive in....

                            After getting my bike back from a friend's winter garage storage I've decided to hell with it, I'm gonna try getting my second gear fixed. I've put it off ever since I bought it almost 3 years ago and it'd be nice to have a bike I can actually hammer the throttle on in 2nd.
                            I'm going to start on it in a couple of weeks and I wasn't sure if I should order the side cover gaskets or anything else I might need. I'm going to do it with the engine in place-because it's gonna be a parking lot repair type thing. I'm going to take my time on it since I've sorta lost my urge to ride all the time. (Too many idiots on the freeway in increasing numbers to ride everyday to work and a wife that worries too much as it is.)
                            Last edited by jrm000kc; 04-10-2016, 06:15 PM.
                            79 SF
                            Raptor Auto CCT, octopus-less, tapped/plugged fuelcock prime ports, new shorter handlebars, original stock Yamaha seat (w/ Octo routing diagram), looking for stock grab-bar/sissybar/backrest.

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                            • #44
                              I would think starting you own post/thread would be a good idea...I'm sure
                              you don't want to hijack this members post...a little confusing to be replying to
                              two different threads within one post...see my point ???
                              79 XS 1100 Special "Basket Case"

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                              • #45
                                Finished...

                                Didn't see the last few comments before I finished, but despite my "hack job" it seems I was successful... Took me about 3 hours to get the gears back in, but I put the bike back together & it shifts into first gear for the first time since I've had it!
                                >>Insert clever statement here<<

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