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Bike won't shift into 5th gear

Discussion in 'XJ Technical Chat' started by Ahamay, Apr 28, 2007.

  1. Ahamay

    Ahamay New Member

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    Hey everyone, was wondering if anyone has had trouble with their XJ shifting gears. My bike is a 1982 XJ650J Maxim. My problem is that I have had the bike twice not shift out of first gear. I finally got it un-jammed and it worked okay. Now it happened to me again yesterday and now I can't get into 5th gear. I can shift all gears fine but when in 4th and I try to shift to 5th the gear lever is just stuck! Could one of my syncros on the gears be out or something? Thanks to anybody who can help me out.
     
  2. KiwiXJ750D

    KiwiXJ750D Member

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    Does the bike sound rattly? It could be parts of the plastic primary chain guide falling down and jamming the selector. Normal symptoms are bike will only go into 1st and neutral. Common on XJs.
     
  3. Robert

    Robert Active Member

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    Ahamay, welcome and boy, do I have some bad news for you. Your starter chain guide just did the parts dance all over the internals of your transmission. The good news is, as Kiwi pointed out, it is plastic. The bad new is that the only way to replace it is to pull the engine and split it. Another point, your tranny doesn't have syncros so don't fret about them. It is a two person job to pull the bugger and will take a day or two for an experienced person to wade through. I bought a new one from BikeBandit for $21 two years ago and it took me a few days to get it all back together again. There is hope. One of our esteemed members figured out how to VERY carefully fish the broken parts out of his case through the starter hole. While this will work, it is a pain to do and does not fix the problem. It will get you home in a pinch however. Hit the search fuction off of our Main Menu and do a quick read on the topic. Key work "starter chain guide".
    Best of luck and welcome to the gang.
     
  4. Ahamay

    Ahamay New Member

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    Hey guys thanks a bunch for the information. I will try my best to get working on it.
     
  5. KiwiXJ750D

    KiwiXJ750D Member

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    Have you got a manual or done anything like this before?
    You need to get inside the cases and there are some tricks to it. You might as well replace the primary chain while you are in there too. I saw one so loose that since the guide had disintergrated the chain was smacking into the top of the case. These chains should not have slack, let alone over an inch of freeplay 8O .

    Anyway best of luck, let us know how you get on.
     
  6. Ahamay

    Ahamay New Member

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    Yeah I've got a manual and I've already had the bike completely apart. Which I would have caught this when I had the engine removed for painting. Oh well, Murphy's Law :? Thanks a bunch for the info
     
  7. KiwiXJ750D

    KiwiXJ750D Member

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    It is always the way. Have a good look at that chain too, don't want to have to go back in there again.
     

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