xj750 stuck in gear

hey all-

New to the forum, and haven't even owned a bike in more years than I care to admit.

Here's the deal-
Just bought an '83 xj750 from a guy for super cheap cuz he couldn't get it out of gearand it had sat in storage for about 3 yrs. I opened it up expecting to find a broken shift pin. In fact there were two broken pins, which I replaced. But I still can't get the thing to shift at all. Suggestions?

Also, there was no clutch handle, so i put on a new one, but can't get the cable adjusted tight enough to disengage the clutch at all.

ALSO- Cant get the oil filter housing to move. Previous owner drained the oil some time ago, so I would like to put in a new filter before I fill 'er up.

Thanks for your help!

 

How many miles on the Bike?

What is your level of wrenching skills?

Search:

Clutch Cable Replacement and adjustment
Author: RickCoMatic

 

Welcome to the site ephlat66

Did you try to rotate the shift drum while you were replacing the shift pins?
The gears may be lined up tooth to tooth and therefore won't shift without rocking the bike or having the engine running.
The primary chain guide may have dropped chunks into the channels on the shifting drum and be preventing it from shifting. (common problem)

The bike has sat for 3 years, the clutch plates may be frozen together and will take some force to break it free. After my short winter storage my clutch wouldn't dissengage, With the engine running, I shifted into 1st and the bike lurched forward and stalled. The clutch has worked fine from that one shift onward.

The oil filter housing (if stock) doesn't turn. You need to remove the bolt on the end of the filter housing to be able to remove the housing. Be careful the head does round easily if someone has over tightned it, use a good socket to remove the bolt.

 

Use a 6-Point Socket on that Oil Filter Bolt and Impact the handle of your Ratchet with a firm blow from a hammer handle.

Several blows ought to get that Bolt turning. Don't try to get it off there without a 6-Point Tool. It rounds-off too easily.

 

About 62k to answer the first question.

And mediocre to answer the second.

 

If you have Primary Chain chunks in the grooves of the Gear Selection Drum, you are going to need Major Surgery ... or, follow the advice of those who have successfully gone through the Shifter side hole and managed to get the chunks out.

No easy feat.
Time consuming and labor intensive.

But, if you can get those fragments out of there ... you may be able to get the drum cleared of the fragments that are preventing the gears from sliding.

I hope one of the Members who has recently done this will pitch-in and give you a Play-by-play on what you need to do.

I haven't done it the way I heard it was done by one of our Members recently.
I have always had to do the Chain Guide as part of the job which meant considerably more dismantling of the engine than what you want to hear about ... I'm sure!

 

Previous owner could have used this advice, because this bolt is unrecognizable as a bolt. It's been completely rounded to the point that previous owner took a hack saw blade to it in an attempt to cut a slot for a screwdriver. Good grief.

 

As far as the filter housing goes, i too had the same issue. I had to take my saws all and cut the housing off. I then went to ebay and got a used housing. I bought the new bolt from parts unlimited thru my yamaha dealer. Way cheaper than an OEM bolt.
Good luck

 

You don't need to tear up the filter housing.

The seal on that bolt is an o-ring about 1/4 inch into the housing. You can safely grind and file the head off that bolt. Then pull the housing off and use your favorite implement of destruction to remove the remains of the bolt.

The hole the bolt passes through is chamfered at the front of the housing. If you're careful you can do the last bit with a file until the chamfer is visible. Then there will be no evidence of your surgery.

I believe our local parts guy stocks the bolt, which has the by-pass valve built in. HEY CHACAL!

 

go to a sears store and buy a bolt out kit these things work awesome even on rounded off bolts they are costly 50 bucks for the bigger set but they have saved my but a few times in the last two years.

 

Just done this a couple of months back. I had chunks of the primary chain guide wedged in the selector drum. I found these chunks by mistake. I had taken off the case cover to hit it on the buffer to polish up the aluminum. I noticed that when moving the gear selector peg off the case, I couldnt get it out of first. Since I just redone the heads and valves, I was a little bit peed off. Anyways, after polishing up my cover, I took a flashlight and shinned it in the shifter side hole. Thats when I saw the black chunks just sitting there wedged. Take a pocket screwdriver and about 1 1/2 hours fishing at it to get it out. Now it shifts through all gears. Hope this helps.