View Full Version : XS 650 Transmisson help!!

01-18-2011, 8:36 PM
Alright had been very reluctant to split my cases myself, but after being charged $50 just to be told that the cases needed split and that it would cost me upwards of $1000 to repair, I decided I just have to take the plunge and do this stuff myself. Well I have a factory manual and read here at the forums alot. Anyway splitting the cases sucked, but after heating it up with my garage heater, it finally yielded. Well I found some nasty stuff earlier in my oil filter, bits of gear teeth, and part of a cotter pin? It looks like I lost the cotter pin on the shift fork



Guess that then got cauught up and allowed it to wallow around. I think my first gear should not look like this




Anyway tomorrow I am going to clean eveything up good, order a used transmisson and whatever else I need. Any tips on what else I will need for reassmbly? I am hoping that installing the new trans misson won't be too bad and I hope I can call upon the knowledge base here to help me out. Actually I am fairly proud of myself for getting this far. BTW, when this happened the bike still ran good, so I think the top end was spared. Want this right so what else should I check while I am in here? Thanks all!! BTW, I have posted this at a few other sites in hope that I can get some advise.

01-18-2011, 8:37 PM
BTW, the shift fork that lost the pin after resetting seems to have side to side play where the other two do not. Is this normal?

01-19-2011, 9:32 AM
you can replace the cam chain and guide from the bottom end, if its original id go ahead and do that. also get a trans from a 78 or later and you can order the 5th overdrive sized gear from mikes.
did it shift ok before you took it apart?
just wondering if you should swap out the shift forks also..
other than that all you need is some yamabond to seal it all back together..

01-19-2011, 11:50 AM
I have a complete transmission pulled from a 75'... the only thing you would need to find is the shift drum and forks since I sold those last week

01-19-2011, 1:00 PM
I am not sure if you looked back on your last post about trans repair, but I offered you a spare engine that I have for free and I am in Des Moines.


01-19-2011, 6:10 PM
found this on e bay http://cgi.ebay.com/ebaymotors/80-YAMAHA-XS650-Gears-Transmission-Assy-Comepleat-/220726478297?pt=Motorcycles_Parts_Accessories&hash=item336452c5d9#ht_500wt_913 you will need a set out of 1978 - 1984 previous models had different type of gears i think they can be transplanted