Catastrophic 2nd gear failure!

[Ranger_xs1100]

What he said!!!

Personally, I'd buy an entire donor bike & motor.

I have two spare XS11 motors in my garage. Both came from failed "Boober" attempts and I didn't pay more than $100 for either bike.

There has got to be a couple cheap bikes in your area you can grab a motor from?

In my opinion, that motor is going to be too costly to repair properly.

Thanks Kurt, I completely agree and I appreciate your advise. I've decided to bail on this project and pass it along to someone who is more ambitious than I am about this one.

[dolphans1]

No, don't quit and try to fix it. Don't give up.

[mack]

teardown

If the motor is already out why not split the cases and do an inspection and clean up everything. Switch your big end and crank shells to blues while your in there and blow out your crank passages and all the other oil galleries. It will only add one day on the rebuild. Great opportunity to clean the cases inside and out. All your top end components are probably in good shape so all you'll need is a gasket set. Andreas sells his tranny components in complete sets, but make sure to blow out the oil passages. I treat them like gun barrels and put them and the gears in my ultrasonic cleaner before reassembly and installation. Don't forget the washer swap before you install second again.

[Ranger_xs1100]

Thanks!

Thanks Mack for the great advice (btw your LH is beautiful!), and thanks to everyone else for their ideas and suggestions as well. And based on everyone’s feedback, I feel that this project is over my head, so this SF has migrated to a new home; It has been rescued by another XS11 enthusiast who is looking forward to the challenge of saving this endangered species. And now I can get back to my LH project and hope it turns out half as nice as Mack’s!

[mack]

At least

it didn't get junked. I'm saddened though because these power plants are easy to work on. You would have enjoyed tearing it down and seeing why "keep it simple" applies to these motors. How they transferred the torque efficiently in different directions to accommodate the shaft drive. It really is a marvel.The Haynes manual is very good to explain the "why", but the Clymer's have better pictures. Read together, they compliment each other perfectly. Best of luck brother!