Just did a search on Youtube. Looks like a 750 motor. I do agree with Jetmech the long way is often the quickest.
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XS850 Master Thread
- Thread starter slackard
- Start date
https://xs11.club/forum/repairs/transmission-aa/5292-1st-and-2nd-gear-dremmel-fix-part-1-2-and-3
I believe the link above is a detailed explanation of how to fix 2nd gear on XS1100 from start to finish. I did mine this way which was putting the motorcycle upside down. When I did mine, new gears were still available. I can’t say how much applies to XS850. The XS11 engine rotates in the opposite direction as compared to the 850.
If you sign onto XS11.club there’s at least one regular poster there who has an XS850. In fact, I can think of two.
I believe the link above is a detailed explanation of how to fix 2nd gear on XS1100 from start to finish. I did mine this way which was putting the motorcycle upside down. When I did mine, new gears were still available. I can’t say how much applies to XS850. The XS11 engine rotates in the opposite direction as compared to the 850.
If you sign onto XS11.club there’s at least one regular poster there who has an XS850. In fact, I can think of two.
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slackard
The Mahatma
Cool!.. thanks, Jetmech, for reposting... I've seen this guide years ago, & I dug it up using the web-archive way-back-machine.. Nice to see it still available on xs11.club as well! (also a member there).
Planning to slowly peck away at this... this season, i may just do prep work and keep riding as is, jumping from 1st to 3rd, for now...
Besides the 2nd gear issue, the engine is running super smooth & should be a great highway bike once fully sorted.
Thanks again and stay tuned for updates!
Planning to slowly peck away at this... this season, i may just do prep work and keep riding as is, jumping from 1st to 3rd, for now...
Besides the 2nd gear issue, the engine is running super smooth & should be a great highway bike once fully sorted.
Thanks again and stay tuned for updates!
slackard
The Mahatma
This video is promising.. xs750/850 share almost identical cases, etc.. Will inspect further and follow up.. Holding off on optimism for now.
slackard
The Mahatma
Found this little nugget on reddit.. sounds like 2nd and 5th gears on the xs750 (and likely 850) can com out wo pulling the engine or splitting cases..
reddit xs750 thread
Despite this comment, some others still claim engine must come out. I'll be inspecting everything before I commit to anything.. Stay tuned!
reddit xs750 thread
Despite this comment, some others still claim engine must come out. I'll be inspecting everything before I commit to anything.. Stay tuned!
slackard
The Mahatma
Success! Here's the xs850 gearwheel stack out of the bike. No split cases, no exhaust pull.. So far pretty easy, besides research and mental prep.
![[IMG]](https://i.imgur.com/pvdUEkm.jpeg "[IMG]")
With the transmission drive axle end bearing cap off, the 2nd gear wheel can come out w a snap ring pliers. However the 5th gear wheel is held captive by the #3 shift fork. To release the 5th gear wheel, you need to pull the clutch basket & oil pan. Then from below remove the e-clip from the #2,3 shift fork guide, then slide it out to release the #2,3 shift forks. Then the 5th wheel can slide out the end bearing cap opening.
Next, to remove the entire gearwheel stack the drive axle carrier bearing cap needs to be pulled.
There are 2 things stopping the bearing cap from popping right out;
A: #2,3 fork guide shaft needs to be fully retracted to clear the bearing cap,
B: Oil pump also needs to come out. 3 cap screws hold the pump to the lower case. Two of them are obvious and accessible as soon as the oil pan is off. The 3rd is hidden behind the pickup spout.. so. 3 JIS screws to remove the screen, then 2 small cap screws to remove the spout, then you can get at the 3rd fastener.
The gear dogs on the remaining gears also showing similar wear to the 2nd/5th gears that I already pulled.. Likewise, the #3 gear fork is very worn.
I'm this deep already, and since everything is apart, I went ahead & ordered a complete set of NOS gearwheels & the #3 fork which was pretty worn also Total spend for the 1-5 gearwheels+#3fork, $460.05
Total spend on the bike so far, including everything, purchase price ($200), registration, repair/replace parts, fully rebuilt brakes/MCs w new pistons & all new spiegler lines + a bunch of NOS/Rare spare parts that I'll keep in stock, $3,486.69
Doing pretty good so far and once buttoned up I'll have a basically brand new gearbox.
With the transmission drive axle end bearing cap off, the 2nd gear wheel can come out w a snap ring pliers. However the 5th gear wheel is held captive by the #3 shift fork. To release the 5th gear wheel, you need to pull the clutch basket & oil pan. Then from below remove the e-clip from the #2,3 shift fork guide, then slide it out to release the #2,3 shift forks. Then the 5th wheel can slide out the end bearing cap opening.
Next, to remove the entire gearwheel stack the drive axle carrier bearing cap needs to be pulled.
There are 2 things stopping the bearing cap from popping right out;
A: #2,3 fork guide shaft needs to be fully retracted to clear the bearing cap,
B: Oil pump also needs to come out. 3 cap screws hold the pump to the lower case. Two of them are obvious and accessible as soon as the oil pan is off. The 3rd is hidden behind the pickup spout.. so. 3 JIS screws to remove the screen, then 2 small cap screws to remove the spout, then you can get at the 3rd fastener.
The gear dogs on the remaining gears also showing similar wear to the 2nd/5th gears that I already pulled.. Likewise, the #3 gear fork is very worn.
I'm this deep already, and since everything is apart, I went ahead & ordered a complete set of NOS gearwheels & the #3 fork which was pretty worn also Total spend for the 1-5 gearwheels+#3fork, $460.05
Total spend on the bike so far, including everything, purchase price ($200), registration, repair/replace parts, fully rebuilt brakes/MCs w new pistons & all new spiegler lines + a bunch of NOS/Rare spare parts that I'll keep in stock, $3,486.69
Doing pretty good so far and once buttoned up I'll have a basically brand new gearbox.
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slackard
The Mahatma
The custom 750 ->850 2nd gear wheel bushing/mod is finished!
Def tighter tolerance vs the worn (23.3k mi) oe gearwheel.
My oil relief scratch pass turned up a burr, that I had to sand back by hand w 320, (Paul Brodie, & his student, "fine fingering", look it up).
I called it there, tho could have gone a few thou deeper for oil relief, shrug, 4tpi is wildly fast, even in back gear, oof (lathe people will know *eyeballs*)
Should be fine & nice thing is I have plenty of bearing bronze left over.
Thankfully, I also have another spare/untouched/NOS/NIB 750 2nd gearwheel in stock, plus 2 NOS revs of the mated 5th wheel!
The bushing pressed in neatly (0.0015" press-fit) & bottomed against the shoulder perfectly.
The proud boss, on the 750 wheel, turned perfectly on the lathe 2-3 thou at a time (see previous posts for dimensions/detail, XJBikes Forum).
So pleased! Still need to do final assembly & test flight... fingers crossed...
![[IMG]](https://i.imgur.com/Isuw1V1.jpeg "[IMG]")
![[IMG]](https://i.imgur.com/9t4ilSM.jpeg "[IMG]")
![[IMG]](https://i.imgur.com/DTvg17O.jpeg "[IMG]")
![[IMG]](https://i.imgur.com/8pi8klA.jpeg "[IMG]")
![[IMG]](https://i.imgur.com/znvcKNF.jpeg "[IMG]")
![[IMG]](https://i.imgur.com/XhNetOh.jpeg "[IMG]")
![[IMG]](https://i.imgur.com/WyAEXMt.jpeg "[IMG]")
Def tighter tolerance vs the worn (23.3k mi) oe gearwheel.
My oil relief scratch pass turned up a burr, that I had to sand back by hand w 320, (Paul Brodie, & his student, "fine fingering", look it up).
I called it there, tho could have gone a few thou deeper for oil relief, shrug, 4tpi is wildly fast, even in back gear, oof (lathe people will know *eyeballs*)
Should be fine & nice thing is I have plenty of bearing bronze left over.
Thankfully, I also have another spare/untouched/NOS/NIB 750 2nd gearwheel in stock, plus 2 NOS revs of the mated 5th wheel!
The bushing pressed in neatly (0.0015" press-fit) & bottomed against the shoulder perfectly.
The proud boss, on the 750 wheel, turned perfectly on the lathe 2-3 thou at a time (see previous posts for dimensions/detail, XJBikes Forum).
So pleased! Still need to do final assembly & test flight... fingers crossed...
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Great work, if my 850 has the same problem you have shown me a fix.
This thread is proving to be very helpful thank you.
This thread is proving to be very helpful thank you.
STARCROSSEDMOTO
XS650 Member
Thanks for this. I may have to attempt this mod to mine over the winter, if I get stuck during my 650 build.The custom 750 ->850 2nd gear wheel bushing/mod is finished!
Def tighter tolerance vs the worn (23.3k mi) oe gearwheel.
My oil relief scratch pass turned up a burr, that I had to sand back by hand w 320, (Paul Brodie, & his student, "fine fingering", look it up).
I called it there, tho could have gone a few thou deeper for oil relief, shrug, 4tpi is wildly fast, even in back gear, oof (lathe people will know *eyeballs*)
Should be fine & nice thing is I have plenty of bearing bronze left over.
Thankfully, I also have another spare/untouched/NOS/NIB 750 2nd gearwheel in stock, plus 2 NOS revs of the mated 5th wheel!
The bushing pressed in neatly (0.0015" press-fit) & bottomed against the shoulder perfectly.
The proud boss, on the 750 wheel, turned perfectly on the lathe 2-3 thou at a time (see previous posts for dimensions/detail, XJBikes Forum).
So pleased! Still need to do final assembly & test flight... fingers crossed...
Attachments
aholeinthewor1d
XS650 Member
Hey is it cool if I send you a PM about this?
slackard
The Mahatma
I mean, just reply here.. what's the question?
