XJ 1100 2nd gear issue

So, I've read a few articles on the Maxim's having some 2nd gear issues, and my new bike seems to fit the bill on it. When I'm nice in 2nd gear(barely open the throttle) it's fine. When I jump on it, it pops, cracks, and just makes all kinds of nasty sounds. Now, I'm assuming the dogs are fubar, and I probably need a new gear. My questions are...

1. Do I need to split the case to get the trans out on the 1100? Or can I take one of the panels off of the case to get the shafts out?

2. Do I need a press to get the gears on and off the shaft on this bike?

3. Anyone know where a good source for gears is?

 

There is a how-to to replace 2nd gear without splitting the cases over at www.xs11.com. There is a wealth of experience there regarding this issue. The 1100 motor was shipped with a gear spacer on the wrong side of the gear, preventing the complete engagement of second gear, resulting in the slippage and wear common to all 1100's.

 

OOPS

Bad info. Sorry.

 

hmmm.... yes that is a the normal problem for an 1100, but my xj skips in second just after 4500 rpm's, no matter if i ram it or ease it, and ihave an xj700.....

 

You are fortunate with the 1100 as the engine doesnt have to come out to pull the trans. All you have to do is drop the pan and you are right there at it. I'd suggest lifting the bike up a foot or so as it can be a pain laying under the bike pulling and reinstalling the trans.

And I dont buy the spacer in the wrong place theory. I had an xj1100 with 10,000 miles and a bad trans and another one with 50,000 miles with no abnormal wear on the dogs. I think the problem is caused by abuse and neglect from the rider.

 

Naw, they weren't in the wrong place. Moving them around lets you get a bit more of the dogs engaged, possibly salvaging one that's already torn up.

 

Are the XS 11's & the XJ 11's Trans the same. I thought that the XS 11's were chain drive.

My bike has about 13 k on it and will pop out of second if I get on the throttle too hard. If that spacer swap would help I would like to change it around before my gears get ruined.

Thanks

 

If it already pops out of gear the dogs are damaged and need to be repaired. Moving the spacer around won't fix the problem.

 

MiCarl is correct, the spacers were in the correct position, moving them can correct the problem if the gear is still mostly ok. Check on www.s11.com and search for "dremel fix". It can be done without splitting the case and with only moderate difficulty. The trannys between the xs and xj are virtually the same (XS's are shaft drive) and the XS11 site covers both the XS and the XJ. I have found that the easiest way to access the tranny is to drain the fluids from the bike and hoist the front end up until the bike is standing straight up on its rear wheel (remove the battery first) then you can stand upright and work on the whole thing!
It was and is a common problem on some of them, others never showed any symptoms. Mine was done at 35,000 miles and had never been beat, a friend of mine owns an XJ that has over 150,000 HARD miles on it and has never had a problem.

 

Ebay is a god place to get some used gears, you can pick some up for less than 50$. You can also get a whole engine or parts bike for 150$. I have done the fix on 2 of my 1100's. It is not hard , it just takes time and patience. Look at the XS1100 web site and read about the dremell too fix for the gears, it works great so you won't have to find new gears. When you start working on your bike get the bike as far off the ground as possible, it makes it easier to see in the engine when you are laying on your back trying to install the gears. I did not turn my bike over like the other person did, I put mine on the canter stand and then on a 12" block. I gave me more room to work.
I have done this repair before . If you have specific questions semd me a PM.