engine rebuild need advice please

my 82 xj1100 needs a new 2+3 gear . i have a complete transmission input output shaft and forks off ebay and ready to tear this thing apart. ive never done this before so please any advice is welcome no matter how obvious. i know i still need a gasket set but any info or walkthrough will be greatly appreciated

 

Read through these posts on XS11.com
http://www.xs11.com/forum/forumdisplay.php?f=39

 

also need some direction on what to look out for when engine is apart...

 

those posts dont help because those are only ways to fix certain gears while engine is still in bike. my engine is removed and im replacing the entire transmission shafts and all. my route entails taking the engine completely apart.

 

What you NEED is a SET of manuals, or at least a factory book.

I wouldn't split the bottom end of an XJ with only the Haynes to go by, and I certainly wouldn't even attempt it without a manual at all.

 

I have to add that even WITH a factory manual and a Haynes manual, the procedure is pretty tiring. You need to organize the dismantle process, have assortment boxes and bags ready, and of course all the tools/holders:

 

honestly i wonder if it would be easier to just part out the bike . it has a ton of good parts and im only 800ish into the bike. i guess i have nothing to loose to try and rip her apart but im just wondering if parting out the bike pocketing some cash and making a down payment on a yamaha warrior

 

The way to do it is to go in through the sump. I've fixed 2 XS1100 engines gearboxes and they are exactly the same as the XJ1100.
Remove the clutch and the gear selector casing and the sump and you will fix it without a complete teardown.
I followed the advice given on the XS11.com site and it is very good information.
The only bit of duff info given there is when they say to lift up the selector forks with some strong wire like that coathangers are made of. I found it easier to push them into place.
By the way, if you do decide to part it out, can i have first shout on the carbs? :lol:

 

I believe that it's 1st through 5th they show coming out without splitting the case. My son (who is 17) did this procedure a month ago and just swapped in the gears from my 78 (burnt a hole in a piston but tranny was good). It would be much easier with the engine out (don't need to flip the bike). There are things that you would need to crack the case for (like rod/crank bearings) but not much else goes wrong with these engines.

But if you do decide to split it get a manual. On the XS11 site there is a member who has a pdf of the manuals. I personally like having my own(printed) copy. Both this site and the xs site have great people that are willing to help and great information.

 

well i think ill try that route and go from the side.

 

Just a word to the wise, you can't just do the job by going in from the side, the sump or oil pan needs to come off aswell.
And while you're in there you might aswell do what is known as "the washer swap". There is a washer placed between two of the gear cogs, can't remember which now, but it is well documented on xs11.com. It helps to tighten up the problem gears, which i think is 2nd, helps them stay meshed better.
Anyway, go for it, the bike will be so much better, and it's not as hard as you think.