Yamaha 650 maxim slipping out of gear

Has anyone had this happen.
What exactly is the problem if it slips into neutral under accelaration.
How hard is it to fix. TIA.
Cool.
Srinath.

 

From what gear? Perhaps you have the dreaded early 80's Yamaha 2nd gear issue....

 

Second gear, right?....
The dogs that engage second gear are rounded off, which will make the gearbox pop out of that gearset under load.

It will not get better on its' own. Holding it in gear with your toe will only make things worse.

The only cure is to split the cases and replace the worn parts with new ones.

Pictures

 

Its an 82 and the guy said first gear is where its doing it.
BTW the XS/XJ 1100 site has this method where you out the bike on its head so to speak and open and dremel cut it from under there. Is there anyhting like that on a XJ 650.
Cool.
Srinath.

 

It doesn't matter what gear is misbehaving, you need to pull the engine and split the cases to fix it.

The answer to your last question is no.

No cheating, no magic wand. Unless you can do the job yourself, bring your wallet.

 

The XS Engine has "A way in." The XJ Engine doesn't.

The Do-it-yourself degree of difficulty ... on a scale of 1 - to - 100 ... is 100!

The engine actually needs to be completely torn-down and split apart to gain access to the transmission and shifting assemblies. Top Wrench guys shiver at the thought of splitting the cases on a real old engine.

If you can find a whole good engine ... the swap-out will be cheaper than paying the labor to overhaul your transmission.

Keep your old engine. Following dismantling instructions ... tear it down and learn how its done. Store the parts until you find a tranny and rebuild yourself a spare ...

Or ...

Part the engine out ... you never know when you'll run into some guy who can't get any of the spark plugs out of the head of the engine he's working on ... and be in the market for a cylinder head.

You might break-even or make a buck.

 

After careful examination and re-reading of the venerable Haynes manual, I was more than comfortable splitting my case on my 650. A successful starter chain tensioner later and I was back in business. It is tedious and very specific steps must be followed to the letter but it is not as hard as one would be inclined to believe. Careful forethought and planning will make a very smooth process. I would suggest investing in a factory manual and the companion Haynes. Best two tools you can put in the toolbox for caring for your beast. Also invest in a tube of the new grey case sealant from Permatex, works like Yamabond for case halves. Best of luck.

 

I replaced the 2nd gear selector fork in my XJ. Trick is not to rush it and follow the haynes manual. It took me 2 days working 8hours both days the first case I split. I took my time, read ahead and got to know my friendly Yamaha dealer for the new selector fork.

I don't believe it is incredibly difficult but it is time consuming.

 

Well its not mine. Its belongs to this guy who was thinking of some sorta trade with my 85 maxim 700. I'd suggest he hold it for parts for the 700 maybe.
I cannot really justify the time and effort. I have no garage and I have 10 other bikes all of which are worth more than an 82 maxim. I'd stick to carbs and valve adjustments and gas tank de rustings ... of which there are a plenty too.
Cool.
Srinath.

 

It's not the first big job you'd want to dive into. The time element gets stretched-out according to both ability and familiarity with the project

Then, space really becomes a factor. Even a single-cylinder two-stroke engine takes-up much of a bench. A DOHC 4-Banger spreads-out fast, taking-up space usually reserved for "other stuff not yours" and the promise you made to "not make a big mess and take-off your shoes before leaving the shop" is impossible to keep.

When you drop a little part and need some help finding it ... nobody wants to hear it.

When you get in the groove and have the heater going good, the light you need just right, all your mo-jo working for you ... you find your groove and catch-hell for working late. You promise to turn-down the tunes and not make any noise so the other can get some sleep ...

Two minutes later ... the only remaining part between you and the next level where you score 20,000 bonus points for getting this much done in such short time needs to have keepers tapped-back off the nut.

You think about how you just promised not to make any more noise.
You silently mutter about all the grief this project is causing you ...

But, saving the free world from a terrorist threat means you have to have your bike fixed in case the President calls and needs you to deliver a message ... right???

Bang, bang, bang ...

 

LMAO RickO :lol:

I can't say about the XJ650, but the 1100 can be done. About 8 years ago, I fixed mine, I took what information I found about it on the XS site, rewrote a lot of it with better detail and added pictures for undercutting the gears to help them lockin better. On the 1100 the counter shaft of gears can be dropped out from under the oil pan as long as you have it in 4th gear.

But I never tore into a 650 before so I can't say what your facing with it jumping out of 2nd on that bike.

But yes, one thing you don't want to do is try holding in gear lifting up on the shifter, you'll bend up the shift fork inside for sure. Just double click and skip 2nd, this is what I have to do on my Vmax now, as it's 2nd is gone, but it has so much power it's no big deal.

 

Can someone please let me know the typical parts needed to fix the maxim 650 that has the 2nd gear slipping out. If you have the part numbers I would greatly appreciate it. Thanks so much.

 

C'mon guys. I really need your help with this.

 

You won't know what you need until you get a close look at the transmission and the shift forks.

Since the transmission will have to be lifted-out in order to remove and replace the offending part ... there are some additional parts you SHOULD consider replacing while the cases are split and the transmission out.

The Starter Clutch
The Primary Chain Guide

Just to mention a couple that could cause you headaches down the road.

 

^^^^And don't forget the starter chain guide!^^^^