Shifter problem

When I bought the bike the shifter would not spring up there was no spring you had to work it with your foot to get it into gear. So I took the cover off and there was no gasket so I ordered a new OEM one. When I would tighten down the allen bolts just enough the Springing motion of the shifter would go away like it was rubbing on something but everything appears to be normal, and the springs all work and all the mechanisms seem to be in great shape but when I tighten the cover down just a little bit with the allen screws, the springing motion of the shifter goes away. You can see one spot inside the cover where it looks like it rubbing, but im not sure....

 

My guess would be that 1) the spring may not be routed properly
2) the shift prawls (?) may be slightly bent, the p.o. May have really jammed it hard to shift
I had shifter problems a few years ago,
And I assumed and still believe that overfilling the engine oil can cause problems.
I hope someone else can help you more

 

Post a pic please.

Gary H.

 

Check the parts fiche for the correct location fo the parts for the shift assembly http://www.yamahapartshouse.com . If the shim (thin washer) is in the wrong place the shift lever pin can't seat into its hole and will bind when the case cover is installed.

Also, could you please add the year and model to your signature. There are some significant differences between each model of XJ.

 

I will do that as soon as I get home tonight, thank you.

 

Ok I will look into it, thank you for the info. I also added my model, thanks.

 

Is the bushing between the shift return spring and the shift lever shaft in place? (number 8 on the parts fiche)


EDIT: I was looking at the fiche for 1982, which shows the bushing, but the '81 fiche does not show the bushing. I know that the bushing is present in '82, so it may have been a revision.

I don't see anything that is preventing the shafts to seat fully into their holes, so all I can think of is that there is something wrong with the cover. Put a straight-edge to it and see if it is warped.

I remember having this same problem on an '81 XJ650 that I recomissioned, but I don't remember doing anything to solve the problem other than removing the cover, moving the shift mechanism through a few cycles, and putting the cover back on.

 

Ok will do, thank you. I will report back.

 

Are those three gear teeth meshing right?
Is one behind the other.
They should be even, right?

 

Well I do not know, because the "shifter lever assembly" on the parts fiche, it moves in and out (there is play in it).

 

those teeth have to mesh, the first two pictures are wrong it can't work like that. i just went out and checked, there is no in/out play in the splined shaft, with the cover on.
could have one of the springs have slipped so the shaft can't go back far enough?
i see marks on the teeth where they've been sliding past each other

 

Interesting, thanks I will try and look into it.

 

Exactly. The shafts aren't completely seated.

Gary H.

 

Exactly. I nodiced the misaligned teeth on two of the photos, but they appeared to line up in one photo so I figured the photos might have been taken at different times.

 

Is this a easy or hard fix?

 

Easy. Follow the manual to dis-assemble the shifter selector/return spring apparatus enough to seat the shaft.

Gary H.

 

Took it all apart twice and put it all back together and it worked. I had spring in my shifter! Took it on a test drive and the clutch is still slipping from before, and it was not down shifting, unless I went up a gear and down, kind of like that. Hoping that is a clutch thing as well. How much and how difficult is a clutch?

 

If you haven't gone here and read this: http://www.xjbikes.com/forums/threads/the-information-overload-hour.27544/ then go there and read that.

Then you can go here and read this: http://xjbikes.com/forums/threads/clutches-101-part-1-the-400-550-600s-with-pics.29541/
The 650 clutch is similar and Fitz notes where the differences lie.

The cost is immaterial. A slipping clutch needs to be replaced before the steel discs get damaged (resulting in more expense). Contact Chacal for a direct fit replacement at a reasonable cost, and with more than reasonable customer service. You should also invest in a new clutch cable.

 

The '82-up models got a thicker, stronger spring and requires a support bushing between it and the shaft. The original '80-81 spring is kinda wimpy, and obviously it caused problems, as Yamaha would sell you an upgrade kit that consisted of the later style spring and bushing combined under one part #:

HCP5143 OEM shifter lever shaft TORSION SPRING WITH COLLAR, for use on all XJ650, XJ700, XJ750, and XJ900 engines. This set contains 1 each of the HCP5150 spring and HCP5134 collar, and is what you’ll need to update the weaker spring (without a collar) originally used on the 1980-81 XJ650 models, 1982 XJ650RJ Seca, XJ650 Euro, 1981-82 XJ750 Seca, and XJ750 Euro models.

 

Thank you for the info very much.

 

OK will do, thank you very much for the info.

 

Then you can go here and read this: http://xjbikes.com/forums/threads/clutches-101-part-1-the-400-550-600s-with-pics.29541/
The 650 clutch is similar and Fitz notes where the differences lie.

I took the clutch apart and wondering If we need to replace the clutch hub and basket.

 

That is just light marking from the clutch plates. Dress it up with scotchbrite, give it a rinse, and you're good to go. If there were grooves where the wear marks are then you'd need to consider a new basket.

 

Awesome! Thank you for the info.