Fixing second gear problems with the XJ700

I have to fix 2nd gear. It's appearant when putting the bike into 2nd gear, that somithing is really wrong. The bike appears that it is going into 2nd gear, but it grinds. I'm pretty sure that 2nd gear is stripped. My questions is that I have the motor pulled, what is the best way to access the transmission? Can I seperate the lower case with out taking the whole engine apart? can I turn the engine upside down and remove the bolts and just lift the lower casing off?

 

Not the exact same, but here is a link for the XS11's.

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

There was another user that was working on the same fix. I don't recall seeing his outcome, but once he got it stripped down, I believe he realized that he had to split the case to get at all of the parts on the 700.

 

Wonder what says in the XJCD. >?

 

You might be able to "See" the problem after removing the Bottom Sump Cover.

To "Fix" the problem; you are going to need to split the Cases and go-in the long way.

Have you done everything from Checking the Shift Lever to Adjusting the Throw-Out ... or, does Second Gear grab for a moment and then let go?

 

Second gear engages but when I hit the gas, it grinds like it is in gear but the gear is worn all the way down. I opened the bottom sump and the gears right at the bottom appear to be all good. Is there two rows of gears in whch i can't see the second row to tell if 2nd gear is worn? how do you adjust the throwout? I loosened all the bolts to split the cases, however I can't seem to seperate them. I think I have taken all the bolts out. is it suppose to be exremely hard to split the cases? is there a recommended methode?

 

Stop!
Don't do another thing until you know what and how to go about it.

Splitting the Cases is one of the last steps inn a COMPLETE Engine tear-down.
C-O-M-P-L-E-T-E.
Just about the only thing that you DON'T do, ... is drain the battery!

You really should get yourself a Workshop Repair Manual and review what you've got yourself into.

 

+1 on getting a manual.

If you turn the motor over you'll find almost as many bolts on top as the bottom case.

Here's an example of why you HAVE to have a manual.

Have you taken the "Pickup coil" off?
It's bolted to the top AND botom cases.

Good luck
ab

 

Now, ...

Take a few minutes and FILL OUT the missing details of your Memnership.

Location. (Because somebody near you might be able to help you!}

Signature: Thumbs on your Bike:

Year - Model - Miles - Stock or Modified

 

I have the Manuel. It really just shows you how to split the cases after the complete engine i torn down. By the way, I alreade had the puckup coil out. I have all the bolts top and bottom out to split the cases, however it wont come apart, I am very familliat with working on cars and this is my first oportunity o work on a bike. I want to do this, I have the manual but it's really no help. Is the cases suppose to be tough to split?

 

OK I finally have the cases split. I was missing the bolts behind the oil pump. All gears appear to be OK. Why would 2nd gear be skipping or grinding? Not sure what the problem is.

 

GOOD JOB you're getting there.

I haven't had the pleasure (yet) of rebuilding a XJ although I did rebuild the transmission on my XS11.

I’m going to OFFER the GUESS that your trouble will be in the shift forks or shift cam.
It’s probably over/under shifting, either trying to go from 1 to 3 or not going all the way into 2nd.

Lots of experience here so someone should be along in a while with some first hand knowledge.

Again Good luck
ab

 

Look at the illustrations in the XS.11 Link.

You'll likely find several Dogs and Bosses that need to be Refaced and Undercut.

The trick to repairing Second Gear is to reface the Dogs with a BIAS Cut.
Remove material from the Dog eliminating the rounded-off surface areas.

The dressing of the rounded-off areas needs to be done with precision.
Not only do you have to be careful to make opposing cuts -- on an angle -- to make the surfaces meet. You must also consider that ALL the Dogs need to be dressed such that they ALL mate.
If some are undercut further than others ... they will NOT mate and the weight-bearing forces will be increased upon those that do.

 

Wow. Miss a couple of days, and she is opened up for major surgery.

Like Rick said, the XS link goes through the steps of using a dremel tool to fix the cogs and dogs where the problem likely is. I read on some other posts where some people took the gears to machine shops to have it done as well.

Nothing like jumping in with both feet.

 

OK sorry for the delay in response. after close examination, the dogs on 2nd gear were in bad shape along with the hubs on 5th gear. I ordered a new transmission off of ebay. Hope that it is good. the number 1 shift fork was also badly wore. I will be back on once reassembly begins. This will happn when I recieve the new gaskets and transmission.

I picked up an 86 Fazer. Wow what a blast.

Thanks