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shifting components trouble

Discussion in 'The Garage' started by js2kpdx, Oct 1, 2020.

  1. js2kpdx

    js2kpdx XS650 New Member

    I'm new here, new to the XS650, and new to engine rebuilding.

    I am trying to reassemble the shift drum/forks/star-shaped mechanism. I'm able to turn the star and run the forks through their movements, and this seems to be working fine.
    The problem occurs when I then install the half-moon plate with two bolts on the outside of the case. If I turn the bolts until they are 99% threaded, I can still move the star by hand. If I turn the bolts just a little more until snug, I can no longer turn the star. Does that sound normal? The bolts also appear to be pretty long; they protrude about 5mm into the case.
    I'm following both the factory manual and Hans J Pahl's book.
    In Pahl's book, he shows a photo of the half-moon plate installed with what seems to be the shift shaft sticking out beyond the engine case. When I install mine, the plate partially covers the shaft, keeping it in place. I cannot see any other way of mounting the plate.
    Has anyone encountered this issue? Am I imagining a problem that does not exist?
    Thanks for any help. I will try to upload some photos.

    Attached Files:

  2. SomervilleXS650

    SomervilleXS650 XS650 Addict XS650.com Supporter

    There's a notch/recess on that shaft that mates with the plate. Can see in pic below (where the grime isn't)

    [Edit to add a reassembled pic]

  3. js2kpdx

    js2kpdx XS650 New Member

    Thanks Sommerville, I did not know about that notch in the shaft.

    I went ahead and did it, but unfortunately, I am still having the same problem with tightening down the two bolts holding the half-moon plate. If I tighten them, even to 'snug', I can no longer turn the star piece by hand. Also, if I tighten the screw holding the star in place, I can no longer turn the star by hand.
    I was not able to view your photos.
  4. 5twins

    5twins XS650 Guru Top Contributor

    I think you may have some incorrect parts there. The 2 bolts you're using for the half moon plate are definitely wrong. They shouldn't have flanged heads like that. That will prevent you from folding the lock tab up against the side of the bolt head. And yes, the bottom end of the half moon plate usually fits up next to that shaft, it doesn't lay on top of it. That shaft should stick out of the case about 3/8" or so. I think if you do that, you'll discover a notch in it's side for the half moon plate to fit into .....


    Also notice that the bolt heads are smaller than what you're using. These may be special bolts.
    TwoManyXS1Bs likes this.
  5. SomervilleXS650

    SomervilleXS650 XS650 Addict XS650.com Supporter

    Hmm, weird, I can't see the pics on my phone but here on my computer they're showing up. Reposted a couple more here in case helpful.
    4EC736E7-F7CD-4A6B-BBC1-66542A2D897E.jpeg 234CCBB8-DC16-4D2F-8A27-D67DF717694C.jpeg C4C5E243-727D-412D-AF6B-7CBDA41C4191.jpeg

    In any case, yes 5Twins brings up a great point that I noticed as well....those bolts you've got on your half-moon plate are weird looking. From the sound of it the plate is binding the shift drum. Bolts could be too long or maybe your shift drum isn’t seated right somehow and is extended out further than it should be.
    TwoManyXS1Bs likes this.
  6. js2kpdx

    js2kpdx XS650 New Member

    Thanks for the advice everyone. I ordered new bolts, hopefully they work out.
  7. js2kpdx

    js2kpdx XS650 New Member

    New bolts are in, that problem has been solved.

    However: when I attach the spring to the half-moon and stopper lever, it becomes very hard to turn the star shape by hand. Is that the way it is supposed to be?
    The manual makes it sound like I should be able to run through the gears at this point with ease.

    Then I started to question whether or not I had the two gear shafts and shift forks mounted properly, as I don't know what this should look and feel like. I tried to upload a video of the gears spinning through their movements, but I could not get it to work, so I have attached a few photos instead.
    The gears seem to move smoothly, I just feel like they don't travel very far on the shaft, and I don't understand how each click of the star represents a gear change.
    Maybe I'm over-thinking this, but I don't want to seal up the cases before feeling confident about the reassembly. Thanks for any guidance.

    Attached Files:

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