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 Post subject: Gear change problems
PostPosted: Wed Jul 26, 2017 8:23 pm 
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Joined: Tue Jun 02, 2009 9:55 am
Posts: 6
Location: Uxbridge
Hi Guys

My 43k '04 XB9S Has developed a gear change problem. The change between second and third starts ok when cold, and gets progressively worse as things warm up until it won't shift at all. I've adjusted the clutch and the primary chain, and changed the oil (both), without improving things. I'm a bit concerned that if someone tries to repair it by replacing worn components there won't be any bike left!

Any ideas? Thanks


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 Post subject: Re: Gear change problems
PostPosted: Wed Jul 26, 2017 9:25 pm 
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proff. patpending
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Current ride: Victoria Sponge
Location: Bristol - Gateway to all things good
Is the gearbox output shaft bearing worn out? Can you move the front pulley up and down?

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 Post subject: Re: Gear change problems
PostPosted: Wed Jul 26, 2017 9:36 pm 
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Location: Manchester
:yt:....and even if you cant, remove the blanking plug and inspect the mainshaft needle race :idea:
Also, very common failure is the clutch basket needle race.

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98 S1W
00 M2
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 Post subject: Re: Gear change problems
PostPosted: Wed Jul 26, 2017 10:15 pm 
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Joined: Tue Jun 02, 2009 9:55 am
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Location: Uxbridge
Thanks Guys, gives me somewhere to start.


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 Post subject: Re: Gear change problems
PostPosted: Thu Jul 27, 2017 5:18 pm 
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Joined: Tue May 05, 2009 8:00 pm
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Current ride: Buell X1 2001
Location: southampton
just a thought ,is the clutch ? & primary chain ? , adjusted correctly too

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 Post subject: Re: Gear change problems
PostPosted: Fri Jul 28, 2017 11:42 am 
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Joined: Wed May 06, 2009 1:43 pm
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Current ride: The wife
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Spoonbill wrote:
I've adjusted the clutch and the primary chain

Nutah wrote:
just a thought ,is the clutch ? & primary chain ? , adjusted correctly too

It's always best to check twice ;)

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 Post subject: Re: Gear change problems
PostPosted: Sat Jul 29, 2017 8:35 pm 
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Joined: Tue May 05, 2009 8:00 pm
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Current ride: Buell X1 2001
Location: southampton
:coat:
:rotfl: :rotfl:

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Obey the principles without being bound by them.
Bruce Lee


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 Post subject: Re: Gear change problems
PostPosted: Tue Aug 01, 2017 7:29 pm 
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Joined: Tue Jun 02, 2009 9:55 am
Posts: 6
Location: Uxbridge
OK, I can feel some movement at the pulley, but it's too small to measure, or even see. Not more than 0.5 mm. Is anything more than 0 a fail?


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 Post subject: Re: Gear change problems
PostPosted: Tue Aug 01, 2017 7:43 pm 
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Location: Manchester
Did you remove the blanking plug to check the mainshaft needle race ?

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92 MB
96 S2T
98 S1W
00 M2
01 X1
03 P3
10 CR


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 Post subject: Re: Gear change problems
PostPosted: Tue Aug 01, 2017 10:12 pm 
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Joined: Tue Jun 02, 2009 9:55 am
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Location: Uxbridge
Not yet, I had a quick look through the manual and It's not obvious what to do. Chance of some instructions for idiots?


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 Post subject: Re: Gear change problems
PostPosted: Tue Aug 01, 2017 10:50 pm 
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In the centre of the front drive pulley there's a 'rubber' seal/blanking plug......stick a screwdriver through it and lever it out.
Behind you will see the end of the mainshaft supported by a needle bearing......this should be clean and wet with oil, no corrosion, bluing etc.

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Mithered ta death.
92 MB
96 S2T
98 S1W
00 M2
01 X1
03 P3
10 CR


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 Post subject: Re: Gear change problems
PostPosted: Mon Aug 07, 2017 8:28 pm 
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Joined: Tue Jun 02, 2009 9:55 am
Posts: 6
Location: Uxbridge
OK, thanks. Couldn't see for looking.
Mainshaft looks fine.
Experimenting on the road I find I can change gear if I make it as quick as possible. I normally change gear quite deliberately on the Buell, but if I do that it won't change at all. Synchro problem maybe? Problem is definitely restricted to the 2nd to 3rd change only.


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 Post subject: Re: Gear change problems
PostPosted: Sun Aug 13, 2017 9:49 am 
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Joined: Tue Jun 02, 2009 9:55 am
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Location: Uxbridge
Further experiments mean I've now got a totally inconsistent problem. Sometimes I can't get neutral and stepping on the leaver feels like stepping on a bag of spanners, sometimes I can't make a gear change, mainly between 3rd and 4th now. Can anyone think of one possible cause, or is this likely to be just wear?


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 Post subject: Re: Gear change problems
PostPosted: Sun Aug 13, 2017 5:08 pm 
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Joined: Tue May 19, 2009 6:58 am
Posts: 388
Current ride: 2001 M2 Patina
Location: Burmy Gam
In the dim and distant past of when my M2 was new, it had symptoms like that which were fixed under warranty. If memory serves I think the stealership said the problem was that the detent plate in the gearbox was loose or out of alignment, which I guess would cause the selector barrel to move to positions that don't correspond to a proper gear selection. :?

Maybe someone more knowledgeable can comment if that sounds plausible and if it could also apply to XB gearboxes :)

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