1st Gear Only

So after much patience and work, and many answered questions on here, I've got my bike running pretty damn nicely! But I let my guard down and thought I was good for the year, and naturally, something else fails.. I can only shift into Neutral and First Gear.

Nothing in particular happened right before the incident. I was riding normally, second or third gear, right around 30mph. I stop at the intersection, then pull off. But I can't shift into second gear.

I've taken off both sides of the transmission (clutch side, gear change side) looking for fragments of chain guide or whatever (as mentioned in other similar threads). I found some little thing (not sure what, not hard), took it out, but she still won't shift. Inspecting the gear shift mechanism, there are small bars between two 'wheels' that the gear shift mechanism grabs and pulls/pushes. I've noticed that there are only three bars, and some empty holes where 2/3/4 gears might be. Unless I'm judging that mechanism improperly, and that's how it should be? At any rate, didn't find any loose bars sitting around..

Inspecting the insides, I saw nothing blatant that would cause this problem. I ask the gurus for advice on the matter. I feel I'm so close to having this be my reliable daily driver, I hope I'm right..

Thanks guys!

 

You need to search:

Primary Chain Guide Surgery.

I fear that you have chunks of Primary Chain Guide lodged in the channels of the Gear Exchange Drum. It prevents the Forks from moving the gears to select a different gear.

There is a pretty detailed emergency procedure but I can't find it.
You need to clear-out those fragments.

Search-out that emergency procedure first.
Prepare yourself for some bad news if it doesn't work!

 

I've found a write up on "Tranny Fix 1st and 2nd Gears Dremmel Technique," which details opening up the gearbox with the bike upside down. Is this what you're talking about? Assuming I do this to search for the debris, skipping the dremel parts.

This sounds lovely..

 

It's like pulling Excalibur from the stone.

Not everyone who tried is able or successful. But, if the Sword comes free; The Kingdom is yours!

 

You should look into motivational speaking, Rick. I kid, I kid.

So following the instructions on the linked page, this is what I want to get to:


And this is the general area I should find some debris in:


Is that correct?

 

Yep.
Little chunks of hard rubber chain guide. Mostly right in that area of the shift drum.

But while you have the sump off ... get everything that's loose and don't belong being in there loose and cloggin-up the works!

 

Roger that. Thanks Rick. Hope I get the chance to do this in the next couple days.

 

I don't think this is your problem, but you might check before undertaking major surgery:

I'm reading that the Ventures from the 80s have a problem with the pins working loose from the shifter drum. Symptom is that you can only get so far in the gear sequence then nothing happens.

I believe the same pin would be used for 2nd and to return to neutral, so as I said probably not what happened to you. Worth a quick glance though......

 

That's an XS1100 motor, you can tell by the bottom mount oil filter. The second gear problem is well known with those motors.


I think this is what you are looking for.

Chain Guide Removal

 

I'm about to drain the oil and dismantle the covers, seeking out hardened rubber chain guide crap.

MiCarl:
Unfortunately I can't edit photos on this computer, so I'll use this one:

The wheel to the right of where he's pointing, with the six-angled star thing. This is where the gear change mechanism pushes/pulls the bars going back from that wheel. There are a few empty holes (I could only see three bars). That made me suspicious.

 

We have very similar issues with the Vmax models. It's the shift segment. The pins get pushed out when the tin bends. Use a magnet and try to retrieve the pins and re-install them. Bend the tabs back and it should work again. A new one may be in order. I know on the vmax's they used that defective design from 85 to 98 when the upgraded it and made it impossible to come out.

Sean

 

I think that Selector is worn-out. I think that should be "Tabs" (Dogs) on the end of that Star Wheel like the undamaged one at 5 O'Clock on the mechanism.

With nothing for the Shift Levers to click-over and move ... its no wonder the bike won't shift gears.

Aside:

When that happens ... the non-informed usually apply great force to the shift lever. Trying to "Free-up" the mechanism and get into another gear.
As a result, those dogs get worn or broken ... but, worse is that the Shift Forks get bent inside ... too!

 

Edited: No detail in photo. Looked like "Something else" -- (Massey)

You were right, Rick. Huge chunk of plastic. Too big to fit out through the hole. Had to break it while it was still in the gearbox, which is easier said than done. She can shift into second now. But she's leaking bad, so I cant take it for a test drive just yet..

 

sorry, I'll have to watch my rage when it comes to photos.

But SUCCESS! She runs again! Though after taking off and reinstalling the exhaust, one of the pipes is a bit loose. But that's a thread for tomorrow. My current question is...what about that chain guide? I imagine it serves a relatively important role if it's in there. Should I be preparing to swap in a new guide? And if so, how long will this one likely last?

At any rate, thanks a lot for your help, guys! I actually feel..happy..

 

Good to hear of your success, I'll bet there is a silly grin on your face right about now...
The guide is important. That said, I have read several threads of folks who had the same misfortune as yourself and simply removed the pieces and ran without a replacement for several thousand (in some cases tens of thousands) miles/kilometers. I had the same issue and pulled the engine straight away. Replaced the parts and have put my mind at ease.
What is piece of mind worth? $20 part + hours of aggravating work = quite a bit of pride in your abilities and one thing less to worry about.

 

How common is this problem, and whats the best way to avoid?
83 xj750 max.

 

Common with Bikes that have sat for very, very long periods allowing the Guide to dry rot.

Avoidance: Running the bike and bathing it in oil. Frequent oil changes.

 

Since mine sat in a garage for nine years, I guess I'd know pretty quick? I have put about 100 miles on it before I found the carb problem.