Stuck in first gear

[Rockman]

That worried me too. Its obviously been apart before (butchery evident on screw heads etc) and they probably reused the old circlips. I'll replace them with new ones. Grooves they sit in look ok.

[Eveready1100]

That's good news regarding the shift problem that it was only the circlip falling off with nothing actually broken or bent in there. The discovery of the other one is a mixed blessing. Makes you wonder how long it would have run without it in place if it wasn't for the fact you couldn't select gears and ride it anyway.
It'd be nice to know how they both came to fall off, as they normally don't just come adrift on their own.

[Rockman]

Turned out to be the circlip holding the shift pawl into place. Found it and the washer in the sump, along with another circlip and washer  for a small gear on the other side of the motor (drives oil pump I think). Anyway bike is now hanging by its handlebars in the shed ready for the gears to be removed for the second gear fix.

[Rockman]

No, not fxed yet, but I'm setting up to do second gear as well so both will be fixed at the same time. As for the problem, I'm guessing one of the pins you show as well, unless the circlip has come off the shaft on the quadrant allowing it to slip out and clear the teeth on the gear shift shaft. All will be revealed, probably this weekend if I can make time.

[XSokieSPECIAL]

Mine's now stuck in first gear. The lever moves up & down ok but doesnt feel like its attached to anything. I'm going to pull the motor out shortly to do sencond gear, but I'm curious as to what the new problem could be so I know where to look. Any suggestions.
Phil

 Rockman, did you ever get this figured out? From what I've read it sounds like one of the pins has broken or fell out of the shift drum.

 The view behind the shift cover


The arrows are pointing to some of the pins I have referred to


(photos compliments trbig)

[makzy]

Yeah thanks Jonesy, had a read in my book last nite, there's some info in there about too,

[Jonesy]

I may be telling you how to suck eggs?...... if I am?  sorry. but in the manual theres a section on how to order bearings, scriblles and notes on the attachments are from when I rebuilt an XS motor in the past.
And I've got no idea what i'm doing with imageshack and posting pics?

[makzy]

PS.. miked the crank, maximum 3 thou wear! not bad for 30 yrs,,

[makzy]

 Yeah Peter, figured they'd be around that price, I might ask my local bike wrecker mate  how much he can get them for, saw some info about the colors on Z1 enterprises didn't really understand what they were about so thanks for the tip, found a set on ebay for about $180 i think, but said it was not complete! Thanks, Cheers

[petejw1966]

maksy,
yamaha sells the bearings, cant remember how much they were tho,
 the kits come up occassionally on ebay
but there exspensive usually around $300.
not sure if ur aware of it or not but just go with the thickest bearings (blue)
on a used crankshaft, i think it was shappers on the uk site
 that did a plasti guage check of different colour bearings and the thickest was best
used on a used crankshaft.

[petejw1966]

sorry rockman, thought i posted it
and now cant fint the thread to repost.

[Rockman]

Rockman
Sounds like a broken return spring. (the not feeling connected to anything bit) I recently had this happen to My 4 wheel bike (its a yamaha)
 Chuck the XS up on the centre stand and try going through the gears using your hand to select gears
Jonesy.

Nope - the spring seems to be there, but it wont change gears at all. I cant even put it in neutral, which is a bit of a pain..
Phil

[makzy]

Well Jonesy the cheaper the better, but i always remember the old saying, the bitterness of poor quality lingers long after the sweetness of cheep price is forgotten! I just need a complete set of bigends and mains to get this pile of bits back together, any leads are welcome thanks.

[Jonesy]

Rockman
Sounds like a broken return spring. (the not feeling connected to anything bit) I recently had this happen to My 4 wheel bike (its a yamaha)
 Chuck the XS up on the centre stand and try going through the gears using your hand to select gears

Maksy
As you know I've been out of the loop for a while.....yamaha not do them anymore? or are you looking for alternatives so you dont have to pay premium genuine prices?

Jonesy.

[makzy]

 :-[I've just done my gearbox, cutback all gears, moved the 2nd gear spacer washer, there's a trick to that! got some pics but won't get them on here for a while, sorry,
 What i really would like to know is where do i get main and big end bearing shells from? i've tried some links with no luck! Help??