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1100 tranny rebuild

Discussion in 'XJ Technical Chat' started by photogin, Jul 26, 2011.

  1. photogin

    photogin Member

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    i picked up a xj1100 that needs some loving. this is my first bike and ive worked on cars for years but never a bike. the third gear is useless it skips with any amount of use and second skips under hard acceleration. i bought a gear set off ebay and plan on doing a rebuild . what other parts besides a complete gasket set should i buy and also any tips to doing this? i have a shop manual but i feel it has me doing steps that can be avoided ..
     
    photogin, Jul 26, 2011
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  2. mlew

    mlew Well-Known Member

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    Read through some of these posts on XS11.com
    http://www.xs11.com/forum/forumdisplay.php?f=39
    Pay close attention to the shift forks, they do get bent. It would be a good idea to get think about replacing them. After fixing the gears I recommend "dry shifting" the transmition with the oil pan off to check the grear meshing.
    I have done several of them without removing the engine or case splitting. These articles will explain most of your questions, if you have more PM me and I'll be glad to help.
     
    mlew, Jul 26, 2011
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  3. photogin

    photogin Member

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    well looks like i should purchase some shift forks as well. what about the drum ? does that become damaged ?
     
    photogin, Jul 26, 2011
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  4. mlew

    mlew Well-Known Member

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    Drums don't usually get dammaged, check the grooves for signs of wear at the point where the shuft forks slide and change direction. The forks usuallu wear first.
     
    mlew, Jul 26, 2011
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  5. TECHLINETOM

    TECHLINETOM Member

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    My forks were worn so I MIG welded them up and ground them down to spec.
    No problems yet in around 9000 miles.
     
    TECHLINETOM, Jul 27, 2011
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