meteorgnome
XS650 Member
This is going to be my ongoing project log, and where I gather all my questions. Thanks everyone for the help!
Last year, my transmission started giving me issues- Only got a few months of riding out of the summer before I had to take it off the road.
Symptoms started with difficulty shifting from neutral into first- it would "clunk' into first, as if it was dropping into it heavy
Than a few months later, after a 30 mile ride, I went to start my bike and heard a rattling sound that shouldn't be there- shifting into first was even more clunky than before, but I managed to get on the road- and tried shifting into 2nd and nothing but grinding/rattling- Not a good sound- Managed to quick shift into 3rd and was able to make it home- but that was it for the season.
Now it's time to get back on the road- Don't want to miss another summer!
I'm expecting to find maybe a bent shift fork and some damage to the gears when I finally get into the transmission.
Since I'm taking everything apart anyway, I'm planning on addressing as many things as I can- 'Replace everything that is necessary, and as little as possible'' is the idea- as my budget for this project isn't limitless
Currently, I've made it as far as getting the head off today, along with getting halfway there with the clutch.
Went to harbor freight, and Orielly's- and I ended up buying a 32mm deep Fwd Axle socket- But even that guy isn't long enough!
When I was working on the clutch, I found, sitting right on the bottom of the crankcase, a magnet- which I assume is supposed to be there- and, an 8mm hex bolt- sheared in half (both sides of it) - which definitely IS NOT. I haven't made it far enough yet to see where that bolt could have come from- it certainly wasn't anything that I did- I'm wondering if that has anything to do with the transmission issues I was having. We'll find out soon enough I expect.
So far, I found a few other things that might be issues- Would like to hear some perspectives-
#1. There's rust on some of my cam lobes. How big of an issue is this, and is there a way to take the rust off without replacing the whole cam? - And is taking the rust off in this situation something I want to do or am I looking at replacement? (photos 1+2)
#2. My clymer manual mentions, right before the 'remove the clutch damper assembly' -
removing 1, an outer small circlip, a flat washer ,and then a 'shim'
No shim on my bike. is this a problem? Partzilla has this shim listed, but it is of course 'unavailable'.
#3. Upon measuring my clutch nut, I discover the ... washer? that's directly under the nut is folded up on two opposite sides, as if hugging the nut. It doesn't look like it should be that way. It looks like getting a good grip on it with a deep socket (When i finally find one) is going to be a bit challenging because of it. (photos 3 and 4).
#4 . Rust on the flywheel. On the outer surface as well as some corrosion on the edges- Is this something I need to replace? Bike has been charging fine. (photos 5+6)
#5 Any idea on where I can find a deep socket long enough to hit that clutch hub nut? The shaft is 4 inches long. I tried harbor freight- bought a 32mm fwd axle nut socket at oreillys but even thats too short by an inch at least.
Last year, my transmission started giving me issues- Only got a few months of riding out of the summer before I had to take it off the road.
Symptoms started with difficulty shifting from neutral into first- it would "clunk' into first, as if it was dropping into it heavy
Than a few months later, after a 30 mile ride, I went to start my bike and heard a rattling sound that shouldn't be there- shifting into first was even more clunky than before, but I managed to get on the road- and tried shifting into 2nd and nothing but grinding/rattling- Not a good sound- Managed to quick shift into 3rd and was able to make it home- but that was it for the season.
Now it's time to get back on the road- Don't want to miss another summer!
I'm expecting to find maybe a bent shift fork and some damage to the gears when I finally get into the transmission.
Since I'm taking everything apart anyway, I'm planning on addressing as many things as I can- 'Replace everything that is necessary, and as little as possible'' is the idea- as my budget for this project isn't limitless
Currently, I've made it as far as getting the head off today, along with getting halfway there with the clutch.
Went to harbor freight, and Orielly's- and I ended up buying a 32mm deep Fwd Axle socket- But even that guy isn't long enough!
When I was working on the clutch, I found, sitting right on the bottom of the crankcase, a magnet- which I assume is supposed to be there- and, an 8mm hex bolt- sheared in half (both sides of it) - which definitely IS NOT. I haven't made it far enough yet to see where that bolt could have come from- it certainly wasn't anything that I did- I'm wondering if that has anything to do with the transmission issues I was having. We'll find out soon enough I expect.
So far, I found a few other things that might be issues- Would like to hear some perspectives-
#1. There's rust on some of my cam lobes. How big of an issue is this, and is there a way to take the rust off without replacing the whole cam? - And is taking the rust off in this situation something I want to do or am I looking at replacement? (photos 1+2)
#2. My clymer manual mentions, right before the 'remove the clutch damper assembly' -
removing 1, an outer small circlip, a flat washer ,and then a 'shim'
No shim on my bike. is this a problem? Partzilla has this shim listed, but it is of course 'unavailable'.
#3. Upon measuring my clutch nut, I discover the ... washer? that's directly under the nut is folded up on two opposite sides, as if hugging the nut. It doesn't look like it should be that way. It looks like getting a good grip on it with a deep socket (When i finally find one) is going to be a bit challenging because of it. (photos 3 and 4).
#4 . Rust on the flywheel. On the outer surface as well as some corrosion on the edges- Is this something I need to replace? Bike has been charging fine. (photos 5+6)
#5 Any idea on where I can find a deep socket long enough to hit that clutch hub nut? The shaft is 4 inches long. I tried harbor freight- bought a 32mm fwd axle nut socket at oreillys but even thats too short by an inch at least.
