Yamaha XS1100 Cafe Racer Project - Ep 09 - 2nd Gear Fix

Fixing the dreaded 2nd gear issue on my XS1100 Café Racer Project

[baconbrandin]

Wow great video! I am currently working on a xs850 and have the same second gear problem on my bike. I pulled out second gear threw the side and back cut the slots on the cog. I couldn't get 5th gear out this way so i tapped and bagged up the gear dogs on fifth while it was still in the bike and back cut the dogs a little too see if it helps stay engaged. Needles to say this was pretty hard to do but managed to still get it done! i have not had it running since the fix due to the cafe racer conversion i'm still doing to the bike. Well keep up the good work hope to see some more videos of the build!

[dosbox]

True enthusiast right there. Sicker than a dog, still buildinh his bike.

Respect sir.

[terryroux]

Thanks for sharing your experience. I am about to do the same kind of work and this should help me.
Don't you think that it would be a good idea to setup a jig to ensure that the grinding is precise? Otherwise how do you know if the mating surfaces are parallel? And I suppose that it is very important to remove the same amount of material on each dog/slot, otherwise they won't engage at the same time. Was also thinking how to determine the optimal angle?
Or am I being too fussy?

[myvidsoafrica]

Cutting dovetail is just a temporary fix. Cut just second gear innr part by 1mm, put a 1mm washer behind it to move it closer to 5th gear. If you look you wil see that that gear selector drum is designed incorrectly. After thìs fix you can snap change.

[s.e.m]

How did this turn out? I got an xs1100 I was building as a drag bike, but then I was warned not to finish the build because 2nd gear was to wear for drag racing

[SonnyEkström]

Nice job :) Did you pull out those 2 gears on to the side or did you remove the whole shaft from the engine?

[arkangelth]

It appear the Yamaha FJ1100 have the very same issue with is second gear.In time I will do the same.

[kougerat]

That was a good video, I just dropped my xs11 engine off to an engine builder this morning and spotted this usual problem. unfortunately there is also a tooth missing !
so I will probably have to do something like this when I eventually find a knackered used gear replacement.mate.
I'd really like to know how well it has held out after your modification ?
Thanks mate

[yeboahphilip]

Hey that’s a great video out there I really enjoy it so much I have the same second gear problem and after fixing it’s still jumping and making a lot of noise which I have to use first gear and straight to third gear so the mechanic ask me to buy a complete gears to change the old gears so in this case what should I do to have everything done thanks and hopping to hear from you soon sir

[mcphotolock]

great video, thanks for sharing.   This is you tube at its best.  mike

[theend]

Hey man looking good I watched your vids. So jealous of all the stuff you got to work with since I don't have a garage i have to do all my work on the street curve. san diego california is just to expensive for a mexican in his 20s. But I'm wondering if you are building rear sets for this bike? or are you gonna leave the original. I got the original on mine but i'm trying to build more racer type rear sets since this bike was desight more upright.

[timwoodford]

Thanks Drew for the info on this repair I am attempting to do this now ! lol The project I fear the most is putting the output shaft and shift forks back in the transmission . Are there any tips you can give me for putting this output shaft back In the bloody thing ! Thanks for your info thus far !!!

[spymaine]

thanks for trying. gears tagged wrong, could not see what u were grinding,

[hardtailbiker]

In my experience it is the gear selector barrel that wears on one of the curved corners. Either replace the barrel with a new one, or if you can weld the offending curvature to build it up and then grind it smoother so the linkage works properly again

[SaddamPoopStain]

I have an xs11. Would this be the reason that sometimes I would add more throttle and it would almost like it looses power and doesn't accelerate well? The way I got around this was just pulling in the clutch and revving high and letting out and then I can accelerate normally again. Is this my issue or something else?