Is that really my second gear?

Hello I'm here to pick her brain today. But having an issue for several years now. I assumed it was second gear dogs and still might be but soon as it started doing it I just chose not to Rev it above 5000 and 2nd gear. Know that I am thinking about fixing the second gear I have been testing it a little to see what is happening and it's doing a very strange thing. If I put a lot of pressure on second gear around 5000 RPM sometimes less it will literally jump. The bike loses momentum for a second and then slams back into a driving mode. If I continue to throttle the bike it will hold right up over 7000 RPM no problem. Sometimes this happens in first gear what I'm really rapping on it. I would think that if it was second gear it would pop out and stay out not slim back into gear is there a possibility my primary chain is jumping a tooth or my clutch pack is slipping and then regripping I don't know.

 

Don't do that!

Yes you have worn dogs. All of the gears are in constant mesh, so with pressure on the shifter while in gear it will move directly into the next gear if the dogs are worn, or you let off the throttle momentarily (powershifting, which is acceptable on occasion).

Clutch ship is not so viloent. You'd notice power getting 'soft' on acceleraton if it were the clutch.

If it were the primary chain you'd have the problem in all gears, and it would occur without touching the shift lever.

Since this only happens when you are preloading the shift lever, just stop doing that and keep riding until the symptom occurs under acceleration while in 2nd, without your toe on the lever. At that point the dogs are worn enough that you will need to undercut them.

 

Don't think I said I was pre-loading it. It will do it without touching the lever and second gear all I have to do is accelerate to a certain RPM even a smooth easy acceleration will trigger this jump at about 5000 RPM in 2nd gear. Well I guess I have to tackle the transmission next. I so don't want to do that LOL

 

find some used gears and shift forks first, yours are likely toast. while it's in no gear the forks are burning and gears are rubbing where they shoulden't.. if it's bad enough to be repeatable the slots and dogs will need a lot of
metal removed, that makes it real hard to make them mesh evenly again
been there done that

 

Yeah thanks for the info. I was going to just take it apart and Dremel the gears. I guess I'll have to start a gear and Fork fund LOL and how am I supposed to know that the gears and forks that I'm purchasing are in good shape.

 

forks are easy, the tips will be burnt blue, the should be chrome. the dogs and slots should be as square as possible.
i might still have my bad ones, i'll try to get you some pictures

 

skip down half way for the good part
http://www.xs11.com/forum/showthread.php?s=&threadid=5090

 

Sorry, I read you saying that when you put "pressure on second gear" meaning that you were preloading the shift lever. Thank you for the clarification. I agree with Polock, given what I now understand.

 

that's a nice tutorial was clear photos I will definitely reference this when I tackle it thanks

 

I would advise binning them and looking for some good used, if the bike has been used sympathetically even a relative high miler should be good.
Edit to add - never knew you could tip the bike upside down and remove the sump like that!

 

All right guys, I got a new set of gears and decided to do the Dremel work on those gears. Anyway I am having a real hard I had the shaft lined up with the bearing at one point but the fifth gear would not drop past other gear on the counter shaft. What am I doing wrong?

 

Disregard last post I managed to get it to drop in. I want on YouTube and there's a guy who was talking about tapping the counter shaft to get it all the way over and that seemed to help got it dropped in in just a few minutes after that. Now the process of putting it back together begins thanks for all your help

 

Jamings67,
I tried to read all the posts and this may have been addressed. But, this is a VERY VERY common problem with the XS/Xj1100 Motor. There is a procedure called "The Washer Swap" that (assuming the gear is not ruined) will completely solve the problem. Basically you remove a washer from one side of the gear to the other. The washer is about .0025" so you get incredibly better engagement. I've done this SEVERAL times as the owner of FIVE(5) XS1100's. Once done, problem is gone.
This procedure was developed by Bob Jones a pretty well established XS1100 expert, racer, customizer, tuner, and author of XS11 Heaven.

Although SOME advocate using a dremel on these hardened gears, I personally do NOT. #1 making all identical is not likely on the work bench in your home and now we need to re-harden. New gears are obviously UNOBTAINIUM but a DECENT set isn't too expensive maybe $75 on Flea-Bay.

The entire repair can be done WITH the motor in the bike. Some flip the bike, some do not. Done it both ways. Flipping is easier to make the actual "Gear Repair Washer Flip" but all the stuff you need to remove from the bike to make it an easy (and safe) flip makes for a heck of a long day. Personally, I can do it in several hours from underneath (but I have done SEVERAL TIMES!). Plan on spending the weekend on this first one.

If you keep driving it the three dogs on the 2nd gear will get really rounded. They MAY be fine and will respond perfectly to the "Washer-Swap" without any replacement being needed.

I may have some spare gears as I buy up every POS XS/XJ1100 Motor I can find..........

Sincerely,
KURT

 

The XS/XJ11 Forks MAY not show ANY signs of abnormal wear. If this has been going on for a while, you will see the grinding on the edge facing second. Two of the forks are identical, one is different.
I'll post of photos of BAD gears and GOOD gears later tonight.

Kurt

 

I just dropped them back in. I got a set off ebay and it was a little better than mine. I did dremal the dogs and 2nd gear. I had to remove more then I wanted from the 2nd gear. I hope it holds up. I also swapped the washer.