XJ650 stuck in 1st gear: Getting ready to open

My XJ650 is stuck in 1st gear. Possibilities:
1- Disintegrated plastic chain guide
2- Bent transmission gear fork(s)

I would like to have the parts I may need around when I start working on my trans. From what I've read in all likeliness, I will find plastic pieces preventing the forks from moving properly. Likely a disintegrated chain guide, but I'm having a hard time finding out in the forums how exactly that guide is named. My best guess so far is the starter chain guide, named in bikebandit.com "GUIDE,UPPER". See attached photo.

A- Is there another plastic guide that could have disintegrated, that could interfere with my gears change or is that the only one?

B- If I find a bent fork, is that something that can be straitened with some reliability?

Thanks!

 

Yup, that's the part, also called a Primary Chain Guide. Your problem could also be the cam chain guide, but this is less likely. Best to replace a bent fork. Lots on eBay, or see Chacal.

 

I've had this problem on two bikes now and both times it was the Primary Chain Guide. Not really that hard to fix if you take your time and stay organized. First time took 3 months (not very organized) second time about 8 hours from start to finish.

 

holly crap tcoop that is a steep learning curve

 

You missed a possibility: Something in the shifter mechanism itself has come apart or broken.

Did you check that first? It would be a shame to split the cases because of a broken shift pawl return spring.

 

Definitely another possibility. Given the probabilities I observed and were given to me in this thread, (thanks guys btw!!!) I think the only part worth having on hand when I open the patient will be the upper main chain guide.

Another question: Any chance the operation can be done with the patient upside down and removing the mufflers? Anyone has succeeded that way?

 

Are you talking about flipping the whole bike over? NO, you have to pull the motor to split the cases. There is a lot involved here.

Besides the chain guide, you will need a complete engine gasket set, a tube of Yamabond #4 or equivalent, and a service manual.

But before you go to all that trouble, pop the shifter cover off and check the mechanism that lives outside the crankcase, as I suggested.

 

bigfitz52, these are wise advices that come from someone with considerable experience. They are a gift, and I have no choice but following them.
Thank you.

 

I will respectfully take exception to one detail most honored BigFitz.
You do not have to open up the top end to perform this task, just split the lower end. You will not need a complete gasket kit for this, just the lower end. New seals are a must.
If you are set to do this on the cheap, buy a roll of gasket material and make your own side cover gaskets. You will need a tube of Yamabond or the Permatex equivalent MotoSeal® 1 Ultimate Gasket Maker Grey ( http://www.permatex.com/products/motorc ... r_Grey.htm ) along with new o-rings and seals. This should set you back about $50.

 

Duly noted Robert.
Just in case I get a less knowledgeable person in the parts dept, what would be the most complete name for the "o-rings and seals"? What are they for?
Thanks

 

Well I was afraid of that. I called my Yamaha dealer, and I need to specify which O-Rings and which Gaskets specifically that I need...

 

I went down to the local hardware store (Ventura Hardware, great little place with EVERYTHING) with the old o-rings and, after explaining what I was doing, got all new o-rings that were up to the task. Seals are easily obtained from our resident parts guru, Chacal, tell him what bike you are working on and he'll kit up the parts for you at a very reasonable price. He'll have the o-rings too. Like I said, you can cheap out on the gaskets if you have a heap of time on your hands and cut them out of gasket material. Otherwise spring the $40 for both side gaskets.

 

Ok, the O-Ring must be for the shifter pedal, right? Any other O-Rings?

For the drive shaft it must be a gasket?

 

Give me a sheet of Quality Gasket Making Material.
An Exacto Knife Kit.
A Self-Healing Cutting Surface.
A Tube of Lipstick
Scissors, Stick Pins, Masking Tape.
A Half-pint of Jack Daniels.
Some Ice, ...
A Decent Stereo
A Prescription for just what I need for these tired-old aching bones written by a young, hip California MD, or an old one nearing retirement.
Tommy
As Performed by The London Symphony Orchestra and Chamber Choir with Guest Soloists.

I'll make you a pile of them gaskets, better than store bought.
I'd like some dancing girls, too.