gear popping out

i have this issue with my bike ('82 xj650 ) when i shift into 2nd gear i can drive in 2nd gear up to 3,500rpms and then the gear it self jumps out into neutral. if i keep it under the limit of 3.5k and shift to 3rd gear befor that then all the other gears work fine. what can be the problem?

 

I would say either the selector fork or more likely 2nd gear pair has damaged dogs, but if it's either of those you'd have to split the cases to see which one.

Hopefully someone else has other suggestions to try first that don't involve stripping the motor?

 

i'd pull the cover off and just check to make sure the springs are all intact before splitting the cases and ripping into the tranny

 

but it only happening in 2nd makes me think its deeper than that...

 

heres some pics of hat you should expect to see:

http://xjbikes.com/Forums/viewtopic/t=28233.html

 

Go over to sx1100.com and look up second gear fix.
It ain't pretty

 

its not the the lever thats the problem it does go back up, the gear its self drops to neutral. this happens ONLY for second gear. am i really the only one with this problem lol

 

No you're not the only one with the problem, have a look at polocks link (it's XS not SX though, got something else on your mind polock?) I'm voting (officially this time) for knackered dogs, second gear pair :?

If the link works, scroll down a bit and there's some good pics from XS11.com here that show what worn fork and rounded dogs look like (extreme examples, but you get the idea) http://www.xs11.com/forum/showthread.ph ... fix&page=4

 

http://www.xs11.com/forum/showthread.php?t=5090
you can read the whole thing but your really only interested in the grinding part of part two.
it's not as bad as it seems, i did mine last winter

 

Excellent linkage sir Just spent the last ?mins reading through that post. I'm all set now to fix 2nd gear pair should it ever attempt to Uzi me down...

May have to apply some of that to the 'box in the NC27's current power unit too, once the replacement is built, since that has a nasty habit of sometimes dropping from 5th to 4th under full throttle 8O

 

alrighty... do you guys i can still get by with just riding around for now without fixing the problem?

 

The link I provided shows what can happen to the selector fork if you were to "hold" it in gear with the lever, but I'd expect you to be able to skip 2nd for now with no real worries... Personally I'd want to sort it though so unless it's your only ride I'd get looking at it.

 

well if you go 1st to 3rd it won't happen, or just touch 2nd quickly.
i will say that if it is the gear dogs, when it pops out of second there two things (the shift fork and the gear) trying to occupy the same space at the same time and the shift fork gets tore up real bad. don't let it happen often

 

thanks guys! so if i was to get this part and just do a full swap...?

http://www.ebay.com/itm/82-83-YAMAHA-XJ ... df&vxp=mtr

 

or ar those the wrong gears? and i misunderstood?

 

maybe this is more resonable?


http://www.ebay.com/itm/1983-YAMAHA-XJ6 ... 68&vxp=mtr

 

that would be a very good thing to have! might want to put a post on here for tranny gears too, i'am sure there's some dead engines setting around.
i got a set of gears from a member on here and mixed/matched the best of both but when you see how effortlessly they slide apart you'll want to undercut them, i did

 

dang it i dont want to get into this as of right now hahah why me!!! lol really not in the mood to mess around with the tranny -_-

 

Just skip second gear for now then, and build up & modify a "cherrypicked" cluster from ebay & here for when you do feel up to it. That way it's (in theory) a straight in & out swap...

When you see how small the contact areas on the gear dogs are & consider these bikes make circa 70 horsepower & have been going for 30 plus years, it's amazing they've lasted as well...

 

When you step-back and consider your problem; you have to think about a lot more than swapping tranny's.

Three decades of nightmares lie in wait for you as you excitedly plan on eliminating 2nd-gear dump.
You need to do a lot more than swap the exchanges.

Since its a 650, ... and you're definitely popping-out of 2nd; the first thing that comes to mind is that baby was rode hard by somebody.

Look at the Shift-lever.
If it looks bent-out-of-shape; you might need Selector Forks added to a laundry-list of preventative maintenance parts that should rightfully be renewed or replaced when you go whole-hog.

With the Motorcycling Season blossoming you might want to consider finding a good, low-miles, used plant and skip some of the many possible complications involved in "R-'n-ring" a Transmission.

A good used Plant might be worth investigation.

 

650... So it is, forgot about that! Vito, could you add the bike to your sig please fella?

Fair point rick, especially if he's not "feeling" a transmission job. Only problem buying used is it may also have gearbox issues? (unless bought known good from a well known member here I guess)

If a replacement power unit isn't an option financially though, I think the best option would be to build up a "cherry picked" cluster from various sources & *perhaps* do the cutback mod as well depending on the condition of the collected gears. (By cluster I did mean complete cluster as in all gears, shafts, forks etc and a shift drum too)

What are your thoughts on that idea?

 

my thoughts are im all down for building a cluster and swapping it all later but at the same time i want to pry it open swap it and be on with my riding! the thing is i never did these tranny things and if its my first time it takes me a while because i examine everything and am really carefull not to crack anything, and then i clean every part doing it alone is also kinda scary hahaha and boring! but i think ill check out that salvage yard again Rbloke you should remember that from my other post about the intake boots. if i can get the forks and the gears then id love to get it and replace it but if it requires building a cluster then i might just dremell it out and use that for a while.

 

Maybe, except that I post to a lot of different threads on different bikes (look at my post count versus join date 8O ) so can't really be expected to remember each members individual bike, especially when my memory isn't geared towards written word as much as actual oily stuff in hand :lol:

it also helps people out who perhaps have some specific info but haven't seen the first post in a thread (for example, Fitz may come along, see you're going to be in the gearbox and tell you to make sure the primary chain hydraulic tensioner plunger is free whilst your in there, but that only applies to the 550)

AND.... It also stops people like me keeping on at you to add it in your sig lol


On the building a cluster VS just fixing what you have, I was just thinking if you build up & mod a "new" cluster it'd minimise downtime as you could just open it up & swap it out wholesale. If you don't mind having it off the road for a bit longer there's nothing to stop you stripping it, undercutting the dogs on what you have, maybe replacing a fork or two & that should fix it more or less permanently... (that's all you'd be doing with a "built" cluster anyway, just means you could still ride skipping 2nd in the meantime while you do the bulk of the work)

EDIT-: This guy says he's parting out an '81 650 max... http://xjbikes.com/Forums/viewtopic/t=41759.html