Turbo trans issue.

As the weather has begun to turn, I've gotten back to working on the 83 Turbo I got a while back.

As of my last experimenting, it would not start. Today, it fired up immediately and idled well. The choke cable is completely frozen so I'm thinking that if I fix that, it will run in colder weather. At this point, you have to let it warm up before giving it any gas or it will stall. Sounds to me like fixing the choke cable might resolve that as well.

So, I was so pleased that it was running so well that I decided to take it for a spin around my yard. I've rebuilt the front brakes and the bike seems pretty solid, so what the heck.

At first, or should I say, in first it ran great. I couldn't believe how well it ran in fact. Then I got bold and decided to shift into second. Big problem. Loud clacking sound as if second gear isn't engaging. I shifted into third and though the revs were too low, it seemed fine.

So I guess I need to replace second gear. BikeBandit sells a gear for $80. Is this a reasonable thing to attempt? While I'm no pro mechanic, I can hold my own and I do have an excellent set of tools.

Here are some questions related to this. Does the engine have to come out to work on the trans or can I get to what I need to through one of the side covers? If I'm going to the trouble of doing this, are there other things I should do while I'm in there?

I'm starting to believe that if I fix the tranny, get tires and replace the levers, this bike will be road worthy. I had been concerned about the amount of white smoke it was producing, but after riding it for 10 minutes, it stopped.

As always, thanks for the advice,

Greg

 

Did it do this just once, or everytime? I wouldn't jump to a conclusion that the tranny needs an overhaul from one bad shift. Glad to hear the smoke quit for you, that's what it should do.

Looks like a gear replacement is a case splitting job from the manual.

 

Unfortunately, it happens every time I shift it into secnd. There's clearly something wrong in there.

Here's a somewhat related question. I have V3 of the XJ cds. When I go into the 'Technical Publications' section and go to the XJ650 Turbo section, there is a listing for 'Service Manual' When I open this it actually opens the manual for an XJ650G. I can't decide if this is correct or not. I know that the engines are very similar, but I also know they're not the same. Should I be seing an LJ\LK specific manual?

Greg

 

You need the LJ/LK set up. I don't remember seeing any turbo related info in my G factory manual (which is for sale, hint hint). To replace second would require the splitting of the case to pull the shafts to access the gear. Sorry, no easy way out of that one. Are you sure it is the gear and not the selector? I wouldn't be in any hurry to buy parts till your sure what you need. Pull the motor. Good luck and let us know the sordid details. Rob.

 

There is also a 650 turbo engine on ebay right now. Unfortunately they do not ship to west cost or i would have picked it up
Sean

 

Robert, I'm not sure at all that it's the gear and not the selector. Any hints on how I could troubleshoo this?

Thanks,

Greg

 

To my knowledge not without pulling the motor first and splitting the case. Do you have a Haynes manual? I understand that you have the turbo model but lacking the service manual and the CD not having your information, you may be able to get by looking at other transmission assemblies. Look in your CD for another model of a similar year for guidance. And get your service manual! Sorry mate, you've a chore on your hands.