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Well I've finally gotten around to swapping my gearbox to one without any wear. It came from a donor with only 8500 miles. Or so they said. It does look very good though. My main problem here is getting the shaft back in place. I find it wanting to bind at first gear. There is part of the kickstart assembly (just a shaft and a single gear) that seems to be part of the culprit. I have gotten past that point several times but then the shaft is too high to allow the end gear to mate up with the clutch shaft bearing. Is there some kind of trick to get this all back together? It came out rather easy. I flipped the bike on its back and also moved the washer at 2nd and 5th to help with any future issues. Any advice is greatly appriciated.
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80 SG -
The washer swap makes things a little tighter going back together. Just keep working with it, eventually it'll drop right in.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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Tapping the gear set in with a rubber mallet has been known to be effective.2H7 (79) owned since '89
3H3 owned since '06
"If it ain't broke, modify it"
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case
If you look close there is a sharp corner on the engine case inside. For me that little edge/corner was just touching the gear shaft keeping it from going back in. I rounded that corner ever so slightly and the shaft went right in.76 XS650 C ROADSTER
80 XS650 G Special II
https://ibb.co/album/icbGgF
80 XS 1100 SG
81 XS 1100LH/SH DARKHORSE
https://tinyurl.com/k6nzvtw
AKA; Don'e, UD, Unca Don'eComment
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I really appriciate the input. I'll be back at it later this evening. The misses decided the day was too nice for me to be in the garage and has drug me to the local outlet. I'll update when it's back together.80 SGComment
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The only way my Old Lady would get me to leave the geerageOriginally posted by Ctopher87 View Post
1980 XS1100G "Dolly G" Full Dresser (with a coat of many colors
)
1979 XS1100SF (stock-euro mods planned)
1984 XV700L Virago (to be hot-modded)
1983 XJ750MK Midnight Maxim (semi-restored DD)
1977 XS650D ( patiently awaiting resto)
Sometimes it takes a whole tank of gas before you can think straight.
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Well the transmission swap was a success. I've got a few more things to button up tomorrow but it's in and back on the tires. Just something I learned tonight. It's easier to put the shift forks in BEFORE the gear assembly. I wasn't able to get them in after I finally got the gears to mesh. Particularly #2 but it's all in now. It's going to be a breath of fresh air to be able not skip second gear. I've ridden that way for nearly 2 months now.80 SGComment
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Ok so I've got everything back together and lined up the shift pawls and drum. One thing that's kinda off is when I shift up the shifter hangs up top. I can roll on the throttle and I can feel it come back down or I can just put my foot on top and it falls into place. Could I have put the spring on backwards or could this be something else? It wasn't like this before the swap.80 SGComment
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The torsion spring may be broken or not positioned correctly. When the lever is pushed either down or up, the spring centers it again.2H7 (79) owned since '89
3H3 owned since '06
"If it ain't broke, modify it"
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The good news is you can check that WITHOUT draining the oil! Use a car stand under the right frame, so it leans almost like the center stand. You can then remove the shift cover and verify everything lines up as it should, and check to see if the spring has broken. Should only be about 1/2 hours now that you know the bike!
Leaning it will also keep things in place in case something else broke, or is out of adjustment.Ray Matteis
KE6NHG
XS1100 E '78 (winter project)
XS1100 SF Bob Jones worked on it!Comment
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I may have put it on backwards. It's annoying but it's not a big deal. I'll fix it in a day or two. Whenever the new gasket for the shifter cover comes in.80 SGComment
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Hey Ctopher,
Here's some photos from a tech tip about the shifter return spring.
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
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Wasting your time with gaskets. Yamabond or Threebond 1194 is all you need.Originally posted by Ctopher87 View PostGreg
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
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T.C. you've confirmed for me with the photos. The spring is on backwards. I'll most likely take care of it sometime this weekend. For some unknown reason I didn't remove the spring when we flipped the bike and it fell off in process of the swap. I picked it up and laid it to the side unsure of the original oriention.80 SGComment
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Remember to that the spring loops cross each other in order to hold constant tension against shifter shaftOriginally posted by Ctopher87 View Post
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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
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