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  #1  
Old 02-09-2015, 07:24 PM
Wouldstalk Wouldstalk is offline
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2nd gear issue came back

about 6k miles ago I did the dremel fix on my 2nd gear and what i think are the dogs on 5th gear, as well as moved the washer over.

Now second gear is nearly completely unusable again.

I want to just go ahead and buy new gears so that this wont happen again. Do i need to buy both 2nd and 5th gear to fix this problem? Anyone know a good cheap site to buy both? Some sites have them for almost $200 if they have them at all.

Any help would be appreciated.
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  #2  
Old 02-09-2015, 08:16 PM
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DiverRay DiverRay is offline
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If you can get them, buy them BOTH NOW! They are getting VERY SCARCE now. That and a shift fork should take care of the problem.
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  #3  
Old 02-09-2015, 10:33 PM
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Radioguylogs Radioguylogs is offline
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Wouldstalk:

Yes, dogs are on 5th gear, engage into slots in 2nd gear.

You can get 2nd gear from the dealer, but not 5th gear.

Once in a long while, a 5th gear shows up on e-Bay. I was lucky enough to find one when I needed it this winter.

Andreas had two decent transmissions available over the holidays. Don't know the current status.

I hope you show us pictures when you get it apart so we can learn why yours didn't last very long.
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  #4  
Old 02-15-2015, 10:34 AM
mack mack is offline
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What

was the cause of the second failure. This maybe very informative to our members!
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  #5  
Old 02-15-2015, 08:16 PM
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James England James England is offline
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I last saw new gears on www.cmsnl.com
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  #6  
Old 02-15-2015, 09:17 PM
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jwhughes3 jwhughes3 is offline
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If you have to grind the thin, hardened layer off the dogs, it only buys you time enough to find replacement 2nd gear. The softer dogs will wear exponentially faster.

John
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  #7  
Old 02-16-2015, 05:18 AM
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Nightengale Nightengale is offline
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Gears

When I did my gears (with T.C) I found a whole set of tranny gears on eBay and got the whole thing for $25. Just had to look for a while to find it.
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  #8  
Old 02-16-2015, 04:37 PM
clcorbin clcorbin is offline
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So has anyone tried welding up the rounded over dogs and then grinding them back to the original position? One of the problems with welding is it is usually much harder than the base metal, so that should actually help in this situation.
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  #9  
Old 02-16-2015, 04:48 PM
motoman motoman is offline
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Quote:
Originally Posted by clcorbin View Post
So has anyone tried welding up the rounded over dogs and then grinding them back to the original position? One of the problems with welding is it is usually much harder than the base metal, so that should actually help in this situation.
.....you'd think, but unfortunately the heat draws added carbon out of base metal, in this case the part you prefer to stay in place. Broken off engagement dogs would not be a good day.
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  #10  
Old 02-17-2015, 09:05 AM
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Fearthepack Fearthepack is offline
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I live in Orlando FL and plan on taking mine to a local shop who gets all gears reverse cut for $250. I plan on before and after pics. The owner of the shop is awesome and says the work makes them better then new. Maybe I can get a direct connection to the guy that he uses.
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  #11  
Old 02-17-2015, 09:48 AM
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Tenorman Tenorman is offline
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Some gears are available...but you'll have to really search!

When I did my bike last year, I searched for new gears from Partzilla.

The 1st Gear was still available, but they showed that the 4th Gear was, but later emailed me that it wasn't. I bought the 1st gear (about $100.00 with shipping).

I found another 2 NOS gears on eBay...4th and 2nd...bought them...about $100.00 each. I then bought a good used transmission on eBay...another $100.00.

You'll look long and hard to find the 5th gear although they do come up on eBay once in a while...maybe $100.00 if you're lucky.

I ended up using the 5th gear from the used transmission along with the 2nd gear washer. (I had the new second gear cut so I could use 2 washers...one on either side.)

If I had to do it all over again, I would have contacted these people

http://www.fastbygast.com/Catagories...nsmissions.htm

The FJ owners site has a ton of information on these transmissions, because they also had problems with the 2nd gear on the early FJ1100 and FJ1200.

I'm looking for a good used FJ1200 for a new project and it appears that the 2nd gear problems were less apparent on the 1989 and later models of the FJ1200.

By the way...I never found a NOS gear that was undercut...I don't think that they ever existed. All that I found was NOS...NEW OLD STOCK...

Hope this helps....

Tenorman
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  #12  
Old 02-17-2015, 10:02 AM
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Tenorman Tenorman is offline
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Here's a photo of the bike....

I took this photo a couple of weeks ago...a labor of love and it always cries out for something else. But the transmission works great and it screams...

After looking at this photo, I noticed how bad the center stand looks, so that will need to be removed, sandblasted and painted...if Spring ever comes to Western Pennsylvania...but that will be after I clean-out the garage...

[/url]
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Bikes that I have owned and enjoyed...
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1959 Mobylette
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1978 Yamaha XS650
1980 Yamaha XS1100LG
2005 BMW R1150R
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  #13  
Old 02-17-2015, 12:55 PM
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Radioguylogs Radioguylogs is offline
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Quote:
Originally Posted by Tenorman View Post
If I had to do it all over again, I would have contacted these people

http://www.fastbygast.com/Catagories...nsmissions.htm

Tenorman
This sounds like a great solution over Dremel-by-hand. I can't wait for someone to try it and provide a report with pictures.
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'79 XS1100SF 20k miles
'80 XS1100SG 42k miles
'81 XS1100H Venturer 35k miles
'79 XS750SF 15k miles
'84 Honda V65 Magna ? miles
'84 Honda V65 Magna 48k miles (parts bike)
'86 Yamaha VMAX 5k miles

Previous
'68 Motoguzzi 600cc
'79 XS750SF 22k miles
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  #14  
Old 02-17-2015, 01:54 PM
motoman motoman is offline
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Quote:
Originally Posted by Radioguylogs View Post
This sounds like a great solution over Dremel-by-hand. I can't wait for someone to try it and provide a report with pictures.
Considering the make-up and tolerances internally with these trannys , unless your doing a track bike, IMO, save the money for other needed 'fixes.
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  #15  
Old 02-17-2015, 03:06 PM
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thumperjsa thumperjsa is offline
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There is a 5th on ebay now.
http://www.ebay.com/itm/Yamaha-NOS-G...3a2d79&vxp=mtr
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