| Author | Message | ||
     Dsergison  |
my x1 pops out/in gear after lights. I'll downshift to first, and it will klunk in like everything is fine. when I take off I get about 10 feet and it Klunks good. like I didn't really have it in gear. sometimes it gomes out of gear, but usually it stays in. same with upshifts to second. sometimes I miss them for no apparent reason. have I trashed some dogs? I shift deliderately, I don't abuse it. Thanks. Dan | ||
| Walt221 |
I would suspect bent shift forks. I've experienced similar problems with my X1 race bike. Shift forks is what it turned out to be. | ||
| Dsergison |
major repair? weekend job? | ||
| Newfie_buell  |
Check the S1 Manual over in the Knowledge Vault. Its the same bottom end. (KINDA) Remove Primary Cover and all other bits, clutch, then trap door, gear assembly slides out, replace busted parts and re-assemble. | ||
| Buelliedan  |
Actually I doubt its that serious. I would almost bet the retaining clip on the detent plate has broken or the pins have come loose. Mine did on my X1. Pretty easy to repair but you will need some big-••• sockets. I think its 1 7/8 and a big breaker bar to get the nuts loose. | ||
| Reepicheep  |
Could be the clip, but what you describe was EXACTLY what I experienced. The whole gruesome story is in the knowledge vault. Aaron posted about this originally. He called it "shifting into 2.5th gear" Its probably not bent forks. That would be a perfect diagnosis for most sportbikes, but these sporty derived truck transmissions have massive shift forks, it is hard to imagine them being bent. It could be the retaining clip, but I would not expect that to be so localized and repeatable for a half engaged 2nd gear. I would think that would be "stuck in one gear" or something. In my case, it was a case of worn dogs, with a confounding factor of a trashed 5th gear drive assembly, which had chewed up my mainshaft badly. The main symptom you describe is likely the 2nd gear pair dogs. I have tons of info and pictures in the knowledge vault, complete with pictures of the worn dogs, and diagnosis opinions. Getting the tranny out is really simple, like Dan said, just some big nuts and a bar to lock the primary from turning (Al sells good ones, easy to make your own mediocre one). Once you have the clutch and stator cup off as a unit (complete with chain intact) you are only about 6 bolts away from having the tranny out and on your bench. Not a big deal at all. At that point, you can give your 5th gear drive assembly a good inspection. If that has to come out you will need some special tools, I fabricated my own that worked well, but there were tense moments. Once that assembly is out, you will probably need a hydraulic press to get the bearings out and new ones in. I just took the fist sized assembly to a dealer. If you need to do this, don't before we talk. In hindsight, I *think* it could be done with the part in place and still on the bike. Harder for a shop, but easier for the home user. If it is just the dogs, you can break down the tranny yourself if you are careful to keep track of what goes where in what order. Its not impossible, but will take some attention to detail. You can also start with a pile of parts and use the manual to end up with a working tranny, but many of those parts look *almost* identical, so sorting out which goes where can be a real chore. If you need to replace your mainshaft or counter shaft, there is one bearing you will have to pound out, but you can pound it on the right race so you don't destroy it and can reuse it. I was able to do it with a strong will and a sacrificial piece of PVC pipe, but it was a little tense. Replace the gears in pairs, the manual shows a nice diagram which shows you which set has the problem. It is a daunting job when you look at it, but doing it (especially if it is just the dogs) is really not that bad. Looking back on the job, it was (so help me) a lot of fun. At least the dogs part. The 5th gear drive assembly part was just plain old freaking scary. One final note. I did all this, everything was fixed, and about 5000 miles I thought it came back (but slightly different). It was now only doing the "pop" on full throttle accelerations in 2nd gear right as it neared redline, and would sometimes pop more then once. In that case, I traced it back to the D220 rear I was running. It was just tire hop, but felt nearly identical (and was suprisingly violent). | ||
| Reepicheep |
Oh, and I always shifted gently as well, never power shifted. But I suspect my trashed 5th gear drive assembly was putting extra stress on the dogs for quite a while though. | ||
| Captainkirk  |
What Reep said. My own sad story is in the KV as well, but I rather suspect a broken e-clip, worn detent plate and/or shift drum pin backing out before I'd point the finger at the dogs or forks. It's a fairly easy job to get at the source; just pull the primary cover and rotor/clutch basket assy. and it's all right there. You can change your primary shoe while you're at it. It's all in the KV. Good luck! |
