Yamaha XS1100 Cafe Racer Project - Episode 41 - Gearbox Surgery

[@haydenpruitt5199]

Not a waste of time. You're saving all of us owners with your vids

[@georgejoseph7063]

Guys, I just completed re-installing a new transmission, after 2nd gear was completely seized to the axle drive shaft, 2nd gear actually broke when I tried to press it off. I want to share some details of my experience/observations, that others may find helpful. As Andy stated previously, when installing the transmission, you must be in 4th gear and try to get the middle drive gear and 1st gear almost all the way to the end of the axle drive shaft, without it falling off. What worked for me was sliding the collar out from first gear and just letting it hang between 1st and 4th gears, while you get the middle and 1st gears lined up, that makes it super easy, now, once they're in, you can do the wiggle thing and slide the collar back into 1st gear and get the axle drive shaft to line up with the bearing/hole on the clutch side. Next, before you get the axle drive shaft completely seated (keep in mind...a hammer is a hell of a tool, sometimes a few gentle love taps are required) start sliding the shift fork bar in from the clutch side and inserting the shift fork #3, then #2 from between the gears. Be aware, there's a flat spot on the shift fork bar that must be in the right position, or it rubs on the middle drive gear. I then started getting shift fork #1 installed and this was a real pain, because there was not enough room to get the fork in, I just needed a couple millimeters, so I turned the shift cam/drum just enough to move the #2 shift fork up enough and was able to get the #1 shift fork up far enough to get 5th gear in. It only took me a million times, putting the transmission in and out, but once I figured out this method, I could take it out and put it back in, in no time at all. Once again, keep in mind...a hammer is a hell of a tool....don't break the damn thing, just gentle love taps to get the axle shaft properly seated. Good luck Guys...hope this helps, I did the install with the front of my bike lifted with a hoist, like it's doing a wheelie, so it's high enough for me to sit on the floor in front of it and get access.

[@paulnel1526]

Have now ridden the bike to work for a week. The gearbox is great. Awesome to be able to use 2nd and the torque the 1100 motor supplies. Thanks again for the video and tips.

[@bobandre53]

I've done it mate!! A million thank yous from accross the pond! 4th gear is a MUST! Andy I really appreciate your help I couldnt have done it with out you mate. Thank you so much.

[@tomservo5347]

Hey Andy. A friend mailed me not just 2nd gear-but the whole set along with re-worked shifting pawls. Eager to get started and finally have a bike I can accelerate as hard as I please with.

[@ANDY5]

+James Robert XSellent 👍

[@timwoodford4805]

Hi Andy I didn't have to stand on my head and face mecca don't know what direction that is from here anyway lol . I bought a complete bottom end from a xs 1100 midnight special and used the gears out of that and completed the work I was doing on the gearbox on my xj 1100 and thanks to you and Steptoe and some other fine motorcycle enthusiasts out there ! My motorcycle not only shifts smooth as silk again its a pleasure to ride !!! Thanks to all of you and everyone that puts these videos on youtube ! Thanks Mates ! A bloke from the U.S.

[@ANDY5]

XSellent news Tim, good for you for sticking at it mate.

[@timwoodford4805]

Thanks for all your great clips Andy !

[@miketruwe11]

Thanks for the video! I just finished my 1982 xj1100. I was able to find a good used gear set with low miles on ebay for $100. Shifts really nice and more importantly, stays in first and second gear when I open her up!

[@jimaylward2396]

Well done Andy ya dusted yer self of and came back in fighting form great to see the old best tearing the roads up like a new pup . Very happy for ya 😆

[@ANDY5]

+Jim Aylward Thanks Jim :)

[@paulnel1526]

Thank you kind sir. Just did my '81 Eleven Special. Your video help more than I can say. Did the washer mod.

[@nightster6378]

Success and well done and great vid, I didn't realise the XS's had a gearbox Issue's they were not as popular here as in Aussie, I only hope mine will be ok but won't find out now till about April. I knew the 6's had gearbox problems as in the day mine did, again I hope the 6 I have now is ok as I haven't ridden it yet. By the way I was out tonight watching David Coulthard run up and down the streets of Belfast in a 2012 F1 Red Bull Car, Jeremy McWilliams on a big V twin probably an Aprilia and Ryan Farquhar on something. I have to say the V Twin won the spine quivers, Oh those noises, how can you ever make a woman understand, a crowd of men crossing their legs grinning from ear to ear at the noise while they sit and talk about Knitting and handbags. then a pint of Harp in Robinsons before going home to watch Andy's vids, being a small population we don't get these events much.

[@ANDY5]

Sounds like a great time to me

[@speedster21auer73]

I can’t wait to get mine on the road it has transmission issues and this video should help a ton

[@kudo1261]

Congratiolations on that fine bike! I just love the sound of it! It turned out to be a beautiful machine! From my own experience I know how easy they are to ride in terms of engine torque. Have fun!

[@ANDY5]

+KuDo Thanks Kudo :)

[@franciscojaraespinoza9479]

good job man!!! this motorcycle is a masterpiece and a survivor. You have capture the kando on this machine. thanks for the videos. And i hope you can help me later in my first proyect.(Yamaha XJ 1100 1983). i love the classics!! .................greetings from Chile!!

[@ANDY5]

+francisco jara espinoza Hola Francisco :) Thanks for the comments, and thanks for tuning in. Good luck with the project mate, be sure to keep us up to date.

[@rickvaiBBB]

I changed the entire row of sprockets on an 1100 XJ in a few hours. I drained the engine, took it out, turned it over and spilt the crankcase. I don't understand why you did it that way?

[@vctr92127]

I just pulled the bottom gear shaft out last night ('78 XS1100) to get at a shift fork with a snapped finger. I'm seriously dreading reassembly because of that darned kick-start gear/shaft. I pulled it out as well and will likely be leaving it out. The only concern I have is that 1st gear will be more prone to wobbling/walking. I split the cases earlier this year to fix another issue (caused by my poopy kick-start timing) and am comfortable knowing what parts commiserate with what. I really find no reason to keep that kick-start gear in my bike. You have any input, Andy? Also thanks for sharing all that you've done with your bike. I've had my XS since the end of 2014 and I have been following Andy's Obsessions *almost* from the start. You have saved me countless hours of squinting at low-resolution scanned PDFs of grease-stained, decades-old manuals.

[@eduki]

Andy, thanks a lot for the video. I have mine jumping gear 2 to 3, could you give me any suggestion of what the issue could be? Maybe the selector, or could be a broken gear inside?

[@tonypeters3385]

A good job to have finished Andy, but good instruction none the less. Re the tab washer; I make my own from thin body washers approximately the right diameter. I just cut slots around the perimeter and Bob's ya Uncle! Thin grinder blades work well and only penetrate approximately half the width or less. They work in my racing sidecar!!!! Oi, gotta love Pug's by the way!

[@ANDY5]

+Tony Peters Thanks Tony, yes...we love Pugs, and French Bulldogs, and Australian Bulldogs and, and , and....

[@tommoso55]

Andy what you need is an Abba Skylift for tricky upside down jobs like that.

[@1brandon207]

What shocks are you running on the rear? I’m looking for something similar for my 82 xj1100

[@PickupsAreNotTrucks]

Ok, so the symptoms of this are what? When I’m in first gear on my XS1100, it makes a clunk noise when I get on the throttle hard. Happens easier if my wife is on the back. Only happens under high load. Is this what I have going on? It’s these paws slipping?

[@franchicheikmartins7524]

Hi Andy , have you ever come across an xs 1100 with up to 4th gear only?

[@ANDY5]

Can’t say I have mate

[@franchicheikmartins7524]

Andy's Motorcycle Obsessions ok , I'LL double check mine ,just got it running and I could swear it only goes up to 4th , greetings from San Diego ,Ca. ...great videos ;)

[@ANDY5]

Cheers mate

[@robotsnthat]

Good video, especially the ride at the end. I really hope you don;t need to go in there again.

[@juanacosta305]

Andy, i know its been years but i am doing mine now after watching your video. Is there a reason you can't remove the shift cam as well to take pressure off the forks and giving you room. I am at that point and can't find any information regarding removal of cam. I imagine the shift cam slides out at the end where the shift shaft lever engages it.

[@juanacosta305]

In the case anyone reads this the shift cam can be loosened with removing the lower bolt to move forward. This does make the job a little easier for removing the forks. Trick is that the rear top bolt holding the cam is spring loaded with a ball bearing and has to be pushed upward when sliding the cam back into position, was not that difficult but some might differ. Otherwise the whole job took my maybe 4 hours including the dremel, which I ended up using a nice bit on my dye grinder. Job is done and First and Second gear are smooth.

[@paulsnakerichardson]

hi Andy glad you got your gearbox sorted. must be a yamaha gremlin for 1st and 2nd and 5th gears as i had the same problem with my 98 R1 jumping out of 2nd under load. looking forwards to more vids.

[@ANDY5]

+Paul Richardson Thanks Paul, yes it would appear these type of issues are quite common. The key to avoiding them is regular oil changes with quality oil. Andy

[@scr0ter]

Nice job, just a question about moving the washer to the other side of the gear, makes total sense to me as far as engaging the dogs better but wouldn’t it move the drive teeth slightly to one side of the gear on the opposing shaft, and does that matter.

[@ANDY5]

No mate, it's fine.

[@tomservo5347]

I'm jealous of your shop...I currently live in an apartment and parking lot repairs just plain suck. I need to fix 2nd on my '79 Special...just haven't built up enough courage to go through with it. I'm planning on doing the dremel dovetail fix to it. Great, informative video Andy.

[@ANDY5]

Hi James, I guess it's all relative. We live in a three bedroom townhouse with a single car garage, which is full of bikes. It is a 30min job to clear everything out so I can work on a bike so I envy other people's workspaces too. I always had sheds up until now. Good luck with the fix, just be sure to grind it as much as you can without compromising the strength and do yourself a favor by relocating the washer. Thanks for watching, and the comments, Andy

[@tomservo5347]

Andy's Motorcycle Obsessions We've had some very hot, humid weather and a garage with at least a fan blowing out of the sun sounds like luxury to me. The other problem is I can't just stop and leave if I have to. Leaving my stuff out in the parking lot is just asking for someone to take tools. Our apartment manager also frowns on leaving vehicles in pieces. I have some vacation time coming up. Sounds like the perfect time to take a week and do that tranny. I've lived with it 'popping' in second gear ever since I bought it 4 years ago. It would be a different, much more exciting experience being able to smoke Harleys at stoplights. You recommend going ahead and taking the gear completely out. I've read on xs.com it's possible to do without taking the gear out but I don't like the idea of fine metal dust getting left in such a crucial area. If I run into any problems I might ask you some questions if that's alright.

[@ANDY5]

It's more difficult to remove and replace the entire shaft, but ultimately a better strategy. Also you can't relocate that spacer without removing the shaft, and I believe it is essential in resolving the issue. It would be easier if you can flip the bike but it is a lot of work to do it. Fuel system and all oils will need to be drained etc. I'm happy to offer advice if required but be warned, I've struggled in the past to solve issues over the interwebs. It's always easier if I'm standing in front of it. Andy

[@tomservo5347]

I thought I read somewhere that you need to shift it into a certain gear before disassembly right? I was wondering if the washer swap would fix the slip-but if I've gone that far I might as well do the dovetail to the gear dogs. Everything looks pretty straightforward, the only thing that looks a little hairy are the selector forks. Is it possible to pull 5th and 2nd off the shaft without removing the entire assembly? I should probably order the side cover and bottom pan gaskets because I'm fairly sure they've never been off. (I really hope none of the allen bolts have seized in the aluminum. I had one shear off and it's not fun) I've had guys tell me that they use Yamabond or 'The Right Stuff' gasket sealer alone without a gasket-what are your thoughts? Thanks!

[@ANDY5]

Hi James, yes I mentioned it in the video, you need to select 4th gear. No it is not possible to remove 2nd gear with the shaft or the selectors in situ, even 5th gear requires its selector to be moved out of the way before it can be extracted through the side of the case. I would recommend the Dremel repair and relocating the spacer behind 2nd gear. The selector forks are a pain in the arse but have to be dealt with if you're going to do this so brace yourself and be patient. Definitely get new gaskets. I'm sure there are many modern sealants that will work well, I've never tried. I guess I'm a little old school that way. Good luck mate, Andy

[@kaidenmeade1420]

Why am I counting 6 gears? I’m about to do this but the primary gearing I bought on eBay only has 5 gears on it

[@nbowling10trio]

That's not bad, three hours. Try that with a 2017

[@ANDY5]

Nick Bowling depends whether or not it’s fitted with a cassette gearbox, probably knock it over in an hour. Thanks for watching, Andy

[@dylanbach3333]

Hey so I have 2 full xs1100's one is a 79 and the other is an 81 but I have the 79 which is becoming a bobber and has some wiring problems won't keep itself running anymore I can get it to start and run just not without keep turning on starter even with it choked. But I was wondering where I could find a kick start assembly like sprocket with shaft and kick pedal they say they come with them but I ain't got a one out of two bikes. But the 81 is gonna be a cafe racer just cause the way it sits with new shocks I picked out

[@ANDY5]

Hi Dylan, wow that is a strange one. Go back to basics mate and work your way from the battery forward. Make sure you have power where it is needed and check all your connections. As for the kick start your best bet is to start ringing parts recyclers or jump on one of the XS11 Forums or Facebook pages and ask if anyone has one they're willing to part with. Thanks for watching mate, Andy

[@Alien937]

I knew you'd fix it, nice work again, look forward to more episodes, what bike next?

[@yankeedoodle880]

Mate you must feel like a surgeon, great work, keep it up. :)

[@dylanbach3333]

So about them bikes again how interchangeable would the 79 and 81 like some lighting plugs at different so I was thinking chop them and connect myself with but splices also the mechanical parts are very similar or exactly the same so I was thinking if it fit I could use it. But let me know what you think.

[@ANDY5]

+Dylan Bach Hi Dylan, I have a 1981 RH and a 1980 G, both were Oceana exports so different to US or Europe. But even though they are only a year apart they are very different in both the frame and the wiring looms. The plugs should be okay but the wires may be in different positions on the plug for different models, just be sure to check. One has a ballast resistor and 1.5 Ohm coils the other doesn't. The swing arms on mine are slightly different because there are supple differences in the brake mounting system. Engine and gearbox appear to be the same. Front forks and brakes are different between my two models and things like foot peg, brake pedal and gear lever positions.

[@tomservo5347]

Andy, I finally have some time off and I'm gonna go ahead and get that 2nd gear fixed. I'm heading out to my Dad's farm where I'll have all the time and nobody bothering me that I need. I have a Clymer manual and the right side cover gasket on hand. (I think I can make the left side if it comes to that.) Is it possible to dovetail the dogs with a hand file versus Dremel? It's my transportation to and from the farm so a little extra incentive to get it done, and get it done right. I'll keep you posted.

[@ANDY5]

Hi James, the gears are induction hardened so it would be tough filing them, I haven't tried so I can't answer that. Surely there are low cost die grinders available somewhere where you live? Even if it's an El-Cheapo that you throw away when it's stuffed. I'll be interested to hear how it goes, take photos. You may find this useful, it's where I first saw this repair. www.xs11.com/xs11-info/tech-tips/repairs/transmission/106-the-second-gear-repair-illustrations.html

[@tomservo5347]

After reading various replies to people doing their 2nd gear fixes I saw one where the guy ground out too much-I figured I'd try a round file that would give me ultimate control on how much I dovetail. If it's too much I have a grinder to fall back on. I've heard about the washer swap fixing the slip but if I've gone that far I might as well be sure about it. Thanks for the link. I'll try and take pics but I have no service out here in the boonies on my phone so it'll be delayed. (It's amazing to still have privacy out here as the nearest neighbor is 2 miles away.) I'm honestly quite nervous about this whole deal...but if I'm able to get it right it'll be like having a 'new' old bike over again. Wish me luck, I'm going in.

[@ANDY5]

Good luck mate

[@tomservo5347]

Spent the afternoon disassembling. Got 5th out (I think it's 5th) and there's just a little rounding on the dogs. Second gear however looks pretty wallowed out. I wish I could get 2nd out without having to remove the entire gear assembly. What gear is that hanging down just enough to prevent me from pulling out 2nd on the left side? Can I remove the torx cover and pull that shaft back just far enough to drop it and let me get 2nd out?

[@ANDY5]

Mate, you just have to persevere. It is not a simple task getting that shaft out and back in. I always just keep jiggling things about and it eventually drops out, and you won't know what you did to achieve it. I wish I could be there to give you a hand but you'll just have to grit your teeth, sorry.

[@gregorytimmons4777]

I suppose one could always try retempering the shifting forks or gears where the dog teeth engage the gear. Seems like just a small 45 degree bevel should do it. A shallow bevel with plenty of perpendicular material for the dog to load against. Then with an oxy acetylene torch warm up the little dog fingers to a dull red and then dunk them in oil. It's not a question of if it works but more of NOT getting them too hard, causing them to shatter. That may be a risk not worth taking. I guess i should be thankful my gearbox does not have this problem.

[@etwice5951]

i got a 92 cb750 iv kinda modded a little. i was just wondering if you have any idea how they ride, and if it compares to the xs1100 at all. or is the 1100 a monster just a monster lol?

[@ANDY5]

G'day mate, the XS is a bit of a monster. When they were released in 1978 they were the fastest production motorcycle available on the market.

[@etwice5951]

Andy's Motorcycle Obsessions oh man. I was unaware. Well I love the basket case series man! Sweet bike!

[@NorthernSutherner]

wow , basket case moves ! great job, how long did it take to complete the change for the gears ?

[@ANDY5]

+NorthernSutherner Cheers mate, I think it's about time we made you an honorary Aussie. You could be the FarWesternNorthernSutherner :)

[@ANDY5]

+NorthernSutherner The entire job took about three hours from start to finish. That included mucking around with the camera and adjusting caffeine and nicotine levels.

[@haroldwitham4180]

andy whats the oil pressure suppose to be like ? mine is like 5 lbs to 10 at 1000 idle rpms and at 55mph its like 30 lbs is it a variable oil pump in them?

[@ANDY5]

+harold witham Not sure mate, I have never fitted a gauge. Yours sounds like it should be fine. Yes the oil pump will build pressure as the revs increase and will stabilize at the relief valve pressure.

[@haroldwitham4180]

ok .. well everything seems to be ok i just was wandering ? it caps off bout 40 lbs cold

[@teamster442]

About to try this on my 82 xj1100j Cause i lost 2nd last night.

[@mogmorris6347]

Hi Andy what s it like to do if your just changing the selector forms .cheers

[@ANDY5]

You will still need to remove that shaft assembly

[@mogmorris686]

hi andy finally got round to doing selector forks . video was much needed being able to stop and start it [ bit of a barstewad mind isnt it ] cheers mate much appreciated .did the washer swap by the way

[@drakegbn4]

I might just have to take a trip to you so you can help me with my xs1100. Why? Cause your a genius. By the way, I got the bike running (sort of) I can't get it to stay idling and still loses power while riding. It'll like sputter and stuff. I'm trying real hard it's just another basket case. : )

[@ANDY5]

+Drake giboney Hi Drake, thanks for the kind remarks. Sorry to hear you are still struggling, stay committed mate, you'll sort it out. There is a wealth of knowledge you can tap into at www.xs1100.com.au/forum

[@Garagerat.]

Nice job! was the clutch giving up on 33:45 ?

[@ANDY5]

+TT GarageRat G'day mate, no it wasn't

[@ANDY5]

+TT GarageRat I just played that back and it did sound as though it slipped, I certainly didn't notice it on the day. I will have to keep an eye on it.

[@DanTyson]

You're welcome Andy.

[@kargulvmax]

Miałem Xs1100S w 1989r i problem z 2 biegiem ,kupiłem z sentymentu w 2020r i znów jest ten problem :)

[@ReckedMedia]

Good Video mate enjoyed it!

[@darkstormoutdoors5831]

Thank you for sharing!

[@bobandre53]

VICTORY!!!!!!!

[@ANDY5]

Well done mate 👍 good job.

[@bobandre53]

instagram.com/p/Bzowy7bg6Qj/?igshid=1ms4j78sh6gt1

[@timyanke9559]

@@bobandre53 nice bike! I'm looking for a gears for my xj1100

[@bobandre53]

@@timyanke9559 well i have the xs1100 gears if you want them. I think they'd work but double check

[@timyanke9559]

Yes I am quite sure the xs1100 and xj1100 are the same. I live in Saskatchewan Canada. I think there might be a set at a local bike wrecker (under 200km away) however I am unsure of the condition that they are in. Thanks for replying. What part of the planet are you at?

[@mogmorris6347]

That's selector forks.

[@llewvirtue861]

That's got some go

[@bobandre53]

this video wrecked my bike!

[@ANDY5]

Whoa whoa whoa. What's happened mate? I've just seen your comments. Where are you stuck at?

[@bobandre53]

@@ANDY5 Sorry mate you can delete some of previous comments. I'm stumped! I dont know which goes in first the gears or the forks! can't get the gears in before the forks and i cant get all three forks in after the gears either. I even had a donor engine laying upside down to try it on and still failed after about 10 hrs of trying.

[@bobandre53]

You said it took ya 45 min and I'm like no way! What's the trick??

[@ANDY5]

@@bobandre53 Mate, I'm really sorry that you're stuck like that. There is no trick, it's a bastard of a job. I was going to suggest that you strip the bike down and flip it upside down, but if you have tried that with the donor bike it probably won't help. The bike MUST have 4th gear selected on the shift drum. I put the selector forks up in the engine first, be sure that they are the correct fork for the location. I slid the fork shaft in from the gear lever side to keep the forks in place at first but that didn't work so I used a stiff piece of wire or a long phillips head screwdriver threaded trough a hole in the crankcase just above where the fork selector shaft fits to keep them suspended up out of the way but still allow them to float about, the higher the better. This is where it is a little foggy, I can't remember if I fitted the 5th gear fork before or after the shaft. To be safe I would have it loosely in position first (the fork that is) leave 5th gear off the shaft and offer the shaft up to casing, poke it through on the left hand side (gear lever side) first and then raise it up and start trying to get the gear assembly to all mesh. This can be frustrating and requires quite a bit of jiggling about and you may even need to pull it in and out a few times. eventually you will be able to get the shaft to start in the bearing on the opposite side. From memory, and it has been a while since I did this, your best chance is to slide the gears "almost" off the shaft before you try to feed it up. By that I mean put the clutch side into the casing as far as you can and have the other side gear as close to the end of the shaft without it falling off as you can. Then lift it up and start trying to align them. You will need to try and engage the forks as soon as you can into the grooves on the gears at the same time. jiggling the gears about on the shaft is the only way I have been able to get it all to line up. It usually is just a eureka moment and you feel the shaft engage with the bearing. Then you can fit 5th gear and get that fork engaged and finally fit the shaft for the forks. I hope this all makes sense. Others have been in the same position as you and have finally been able to open a beer and enjoy the after glow.

[@bobandre53]

@@ANDY5 Wow thanks for taking the time to write back! I had it in 1st i believe when i droped it yesterday. I also noticed you had yours jacked up quite a bit so I'll do that too. It definitely is a bastard job but if i can get this my bike will be totally finished. I'm really proud of my build, but 1st was useless and second poped out on the high end too. I did the front fork swap with a 2009 R1 and it rides and looks awesome. I won't give up thanks for taking the time for a good response. I will let you know when i get er done

[@prophaniti1]

It's not just Tasmanians it's Aussies in general who have no idea how to take roundabouts....

[@nuppy.9117]

Fu*k me i hope that speedo is in KM's!!!!