Well, it's time to "Git-R-Done"

It's time to pull out the motor and trans to replace 2nd gear. I will attempt to take as many pics as possible as I am looking to get this done quick and will have full hands while my buddy and I are trying to get this done. Any help and pointers are greatly welcomed. I start at 10 am tomorrow morning. T minus 14 hours and counting. Wish me luck!

8O
Can ya tell I'm a bit nervous?

 

Good luck man. Are you just doing the tear-down tomorrow or do you already have your parts ready to go?

 

... i thought 2nd gear issues only happened on the 700's and 1100s, are tehre any models qwhere it isnt a problem, like the 550s?

 

Let us know how it goes. It's on my list.

 

I have all the replacement tranny. I'm going to rebuild the starter clutch. I also am replacing the starter brushes. I'm really not sure what all else will be involved but I'll be on this site a hell of a lot more over the next couple weeks. Thanks for all the help guys. Like I said, I'll try and keep you up to date with pics.

 

You probably already have read this, but just in case, here is a website that explains the 2nd gear fix.

http://www.xs11.com/forum/showthread.ph ... eadid=5090

 

I actually hadn't read that before man. That's gonna come in handy.

My dilemma is now this. We can't get the bolts to undo the U/J for the driveshaft. It's driving us batty. We just put some WD-40 on it to help loosen bring them loose (Palmer650 should love that). Now we wait to see if it comes loose. Any suggestions.

 

No known trans/driveline issues on the 550, other than a primary chain that likes to rattle a bit at idle and the drive chain itself.

 

Only one: KROIL! Everything else is just wimpy.

 

Got the u/joint bolts loose. Put the bike in gear, doh!

 

Some pics from today. Questions and comment are attached to the pictures. I hope to never have to do this job ever again. All thoughts are very welcomed.

 

Orange O'ring looks like the one that goes around the bottom of the cylinders.

 

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I'm with him. Orange seals are silicone seals, really hi-temp workhorses, and the only place that I know of that use them are the base of the cylinder jugs and the small jug-to-crankcase stud o-rings.

 

So what does it mean that it was in the round oil thing?

 

It means something very very odd was going on with that engine, since it's hard to imagine how it would ever get from "there" to "that place" normally..........

Perhaps it was originally left out when the engine was previously put together/taken apart? A spare that was dropped into the engine by mistake?

 

Chacal,
Do you have these 8 screws with an allen head instead of a phillips head?

 

that round thing looks alot like the sump/oil pump pickup so if that was sucked in there and caught by th escreen(a good thing) then yes someone has done motor work sometime in the past and dropped it in there and never bothered to fish it out. what a nice suprise. Good Gosh that looks like alot of work!!! great pics tho and I know you will enjoy the bike more when you have everything in order.

 

It really is a hell of a lot of work. My back is so sore today, I have rhuematoid arthiritus from head to toe. I can't wait for it to be done in a couple weeks to get out there and tear it up. We're doing the work on the weekends so it'll at least be a couple weeks if we don't need to order anything else.

 

Take your time and do a good job. This is something you only want to once. Put every part under the microscope and if its questionable, Replace it. You'll be able to put many miles on it and it should be as good as new when your done. Good Luck and Keep those updates/ pics coming.

 

I'll add more pics every weekend until it's done. Hopefully I won't have to put a bunch of pics up here as I don't want to spend to many weekends fixing her as I would rather be riding her, you understand I'm sure. :wink:

 

Just so you guys know, there will be a lot of pics not present in this thread. My buddy tim whos' garage this project is taking place in had a couple days off because of the rain and is just about putting this bad boy back together on his own with the yamaha manual. Thanks for all the support guys.

 

I still don't know what this peice is.

 

That is an output gear shim. You will find it adjusts the lash of your final drive gears. There should be another shim there (one top and bottom). You DO want those back in place.

 

I have the two that were on my bike and also got 4 (one in picture) with the trans that I bought to have replacement parts.

 

The round oil thing would be your chain driven oil sump pump. And i agree with the last comment, it was more than likely dropped at some point and the pump had sucked it up... I've just got all the rest of the parts i need to put mine back together, now i just need the torque specs for everything... lol :?

 

That would be the shim you need to keep for the back of the motor, it goes between the case and the little sleeve that seals off the oil from your output shaft. Don't lose those, their a certain thickness. And it'll be slightly difficult getting them replaced with the right ones. If your looking to replace them, check them with a micrometer to determine their thickness. Then look up the proper shim on http://www.z1enterprises.com They've got several other parts for the bike as well. Including the engine gasket kits, oil filters, etc....

 

In about a week or so I'll have my yamaha manual back in my hands here at home near my computer. If you have an '82 maxim 650, I can give you the spec info if you like.

 

This is where the bike is at the moment.

http://www.xjbikes.com/Forums/viewtopic/t=17736.html