First gear woes

[BrettS]

That bike and workshop is way too clean 

[tykwy]

wow, good job.

Can anyone recommend a good Sydney mechanic that won't freak out that I have a sidecar attached who could do the work. I have neither the time nor inclination to do it myself.

I've decided I want to keep the XS, just need to get first gear working because fully loaded she can't launch in second.

[Jonesy :-)]

Good job Bryan,
That's quite a bit work to get through in 7 hours from go to woe
pat on the back for that man there

[hen]

  Great stuff as we get older it's good to have some younger assistance
 

[AussiXS11G]

OK - Gearbox take 2
Jonathon (No 2 son) and I upend Lucrezai, plunder from the donar machine, and operate on first gear.....





removing the middle driven gear assembly allowed for close inspection of the first and second gear dogs.....
these are from Lucrezia - removed...





and replaced with this back cut unit from the donar



comparing assembly of the donar compared with Lucrezia reminded me of the moving of the plate washer from behind the circlip to between 1st wheel gear and middle drive gear to allow more engagement between the dogs and the gear......

 
I went trolling for some terms and explanations for the above and found this on the US site
http://www.xs11.com/forum/showthread.php?t=5090

Anyhow - all back together and working floorlessly - Started abt 11.30am and test rode at abt 6.30pm after going out for oil and spark plugs (got iridium ones) - I was merciless in first and second - lofted the front wheel with no leaping out of gear - job done....very happy now
 

[AussiXS11G]

did it work? you ask......
I am afraid not..... still the same problem unfortunately........
I intend to operate on the machine without removing the engine this time....and will replace the gears with dogs complete..
mine have already been back cut (80k kms ago) and looked ok but the case hardening having been removed bla bla
So I will look at the cogs in my donar machine and maybe try for new parts if necessary.....
I qreally do like gassing the machine from the line.....

[Fred]

A novel way of engine removal I must say

If it works for you

[AussiXS11G]

righteo......pulled the engine from the donar bike, (undid all the mount bolts etc, laid the machine on it's side and shook the engine out of the frame), then very carefully lifyed the engine from mine.





had a good look within and compared the two, turns out that the selector fork on the left of this pic (below) was bent, twisted, preventing first gear from fully engaging, the selector drum not fully rotating. I used the parts from the donar (near new, must have been repaired already) and all appears well with bench testing.



mmmmmmmm.......... polished crank, conrods etc...



 

[Jonesy]

$2K + ........WTF, you did tell them its not a service for a ducati didnt you.

[tykwy]

well now.....what do we have here?
deja vu....
mine is doing this in first - feels like it slips into neutral and back into first, or the rear hits a grease spot and spins up for a split second....
I am told it's a selector problem...
I will know more next week, I intend to operate on mine at home 

Did you have any luck? I've had three mechanics all quote north of $2k to fix it. At that price I'm starting to think getting a new bike would be better.

[tykwy]

Thanks everyone. I'll start ringing around for a mechanic who can take care of it. Problem with having a sidecar attached is a lot of mechanics don't have enough space to look after it.

The engine is definitely overdue for a bit of spit and polish.

[Fred]

"Any suggestions before I spring for a trailer to take the bike down to the mechanic?"

Mate, if you don't have the expertise or the confidence to tackle this yourself at home and want to take it to the shop then I suggest that if the gears or dogs need to be replaced that you have the shop undercut the new one prior to installation.

Talk to the mech, he'll know what you're talking about.

Also, if price is a consideration you could just take in the motor.
I don't know what condition its in but this is a good opportunity to have a look around inside and even have the top end freshend up and some sand (or other type of), blasting done.

[AussiXS11G]

Thx Steps
B

[steptoe]

  good luck,, steady as she goes

the phone will be on

[AussiXS11G]

well now.....what do we have here?
deja vu....
mine is doing this in first - feels like it slips into neutral and back into first, or the rear hits a grease spot and spins up for a split second....
I am told it's a selector problem...
I will know more next week, I intend to operate on mine at home