2nd gear fix, is flipping the bike possible?

[mikeames]

My '82 XJ1100 (Maxim) also had the second (and first) gear issues...same problem with the gear sets. Anyway, with that bike you could remove a bunch of components (seat, tank, etc) and flip the whole bike upside down. Then you pulled the transmission pan and some side engine covers and got to all the gears that way....no splitting the case necessary. I've actually done this and it worked great with that bike. One benefit was all the shift forks were hanging just the right way with the bike upside down...doing it right side up would have been very tough. There's a link on one of the XJ bikes forum with pics and details.
Anyone ever investigate doing this with an FJ100? I'm thinking about buying one that has the 2nd gear issue and I hate the idea of pulling the motor all the way out and splitting the case to fix it... Is it an issue of simply not being able to get the shafts out without splitting the cases?

[andyb]

It's been suggested that you could do it in the frame, but you'll have to split the cases one way or another.  Pull the engine and get it so you can actually see what you're doing, it's not terribly hard to get the motor in and out.

Because of the design, you can't do forks without either chopping things up and welding it all back (good luck with that!) or splitting the cases conventionally.

[mikeames]

So you're fairly certain you can't remove the necessary parts without actually splitting the case? On my '82 XJ, you don't need to split the case to get the necessary gear sets out of the tranny....
I totally agree with pulling the engine if you have to split the case...but IF you don't actually have to split the case then there might be other options....like flipping the bike.
If no one has done it this way on a bike model this old, then most likely it cannot be done this way...but I wanted to make sure no one has done it by flipping the bike....

[racerman_27410]

you can still split the case with the engine in the bike.... i dont know of anyone who has flipped the bike though..... you would have to take absofricking lutely everything off in order to do that... this aint no schwin

drop the engine out or do the job on your back......with the bike upright loading the gearset into the lower case half works great since the shift forks hang down perfectly from the upper case half to mate up with the tranny.


KOokaloo!

[mikeames]

That's good to know...my Maxim is the opposite...the shift forks actually hang in there better while the bike is upside down. Doing it on your back with that bike requires more multiple jointed fingers than most people have attached to their hands...
Thanks all!

[racerrad8]

So you're fairly certain you can't remove the necessary parts without actually splitting the case?

On my '82 XJ, you don't need to split the case to get the necessary gear sets out of the tranny....

No, I am positively sure you have to split the cases. The 82 XJ you are referencing is a totally different engine.

As far as your other inquiry about the starter clutch you can service it when you have the case split for the trans repair. You will not be able to change the starter drive chain without a complete tear down of the engine.

The engine will leak a bunch of oil if the starter is "not" there. It has to be installed or the oil will just pour out on your left leg/foot.

If the oil has not been changed on the required interval, it can cause the starter clutch to slip. Change the oil and ride it for a while and maybe it will clean itself up. If you have to split the case you should install the later model XJ starter drive that uses a one-way sprag instead of the 3 roller system. The new style will never slip.

Randy - RPM

[mikeames]

On the starter clutch I was referring to an '85 FJ1100...you said XJ above....is the FJ the same way?

[racerrad8]

On the starter clutch I was referring to an '85 FJ1100...you said XJ above....is the FJ the same way?

The FJ1100/1200 changed to the XJ1200 in 1995 and now is considered the XJR1300. Same engine generation to the current model year with subtle changes with each moniker change.

Randy - RPM

[mikeames]

Ohh, OK cool. I understand what you meant now. Thanks for your help!

[TheRadBaron]

Based on the title of this thread, I thought it was about doing such a ferocious wheelie that the bike flipped over...once second gear was fixed of course.

[fj1250]

Yeah, you could fix XS-XJ 1100's through the oil pan.
Definitley have to split the cases on the FH.