If the shifting pedal hangs down like a dead bird, even after tightening a double-hard M6 bolt and two nuts, then it's time for the famous words: "Houston, we have a problem". The toothing of the link shaft had finally given up the fight.
For more difficult repairs, it makes sense to keep the laptop or smartphone handy during the work. With the stop / go icons, every repair can be followed at your own pace. That works much better than getting information in general forums. Because there are often cloud walkers and arch supports that proclaim absolute disasters as absolute truths.
Brand / type forums are a safer choice
Replacing the shaft in question seems to pull out a case and puncture it. And because you only have to remove the link. What was immediately noticeable was that the coupling basket lacked a lip. Nothing was noticed while driving, but still ... The lid was dismantled. The plates taken out and neatly set aside. The central nut must then be released to remove the coupling hub. The coupling hub must therefore be blocked. Otherwise you can turn until you weigh an ounce. In the way that has been going well for 100 years with European, American and Russian engines, the clutch hub was blocked. Socket wrench with the long arm on it. Put strength. "PING!" Ah, that was how it came about. The second lip of the coupling basket was now also off.
Then immediately block the hub
After all, the two chipped lips had enough room to secure the Swedish tongs - very neatly with a few aluminum spots between the jaws and the hub. A piece of pipe as a reaction point through the front engine mounts. Strengthening .... Not even putting so much power ... PATS! That Japanese injection molding is apparently crystal clear and super brittle. If those Japanese continue to make motorcycles like this, they will of course never get BSA, Norton and Velocette off the stage.
Or just make coffee?
In the meantime, you are left with a totally destroyed link and it is time for reflection. First some e-mails to acquaintances: "Do you have a link for an XS650?" Then an excursion to a friendly motorcycle store. “A blocking pliers for the coupling hub? Of course we have that. And of course we do not lend any tools. Because then you lost it. Oh. Are those filled cookies for us? That's nice. Will you bring the tongs back this afternoon? "
Good tools: half the battle
With good tools, dismantling the tortured link was a party. In the meantime I had already seen on the Internet that you already have such a blocking tool for 20 + euros. And that is less than the link cost me. But yes: tuition is also money.
Let's see if there are already reactions to my cry for a link
Yes. My most appreciated XS expert asks which engine block number it is. The block is proudly adorned with 'OIL-2500 cc ...' That does not seem to him to me. After some cleaning work I find hidden between the front engine mounting brackets: * X 3 L1 022210 *. I mail the info through and get an immediate answer: there is a link for adoption. Fine! Now just disassemble the front sprocket to refresh the simmer ring around the shift shaft to be placed.
That front sprocket is secured with an 36 mm nut
Would I still try it with the Grand Bahco? Think of scrapes on my knuckles. Because a crooked Bahco has no optimum grip. I look at my watch. The local car specialists are already closed. I'll do my own thing. Tomorrow at 08.00 I will be sharp at my local car parts dealer. The 36 mm cap - and possibly the clutch blocking key - will just cost money. And I never lend them, ever again. Except for people who take filled cookies and bring the stuff back the same day.
In the meantime, the old link shaft has been driven out of its place
The new one is glossy next to his deceased counterpart. Once the front sprocket has been dismantled, the old sealing ring of the shift shaft can be replaced and the entire gear can be put back together. And that I just got a whatsapp about the fact that my upcoming ZGAN clutch has two broken transmission shock absorber springs? Oh well, that's an XS ailment. It is possible to ride it and four springs have not been broken by the way.
The lesson of the story
As has been altered here, that has of course been done. The approach 'If it cannot be done as it should, then it should be done as it can' is a patch.
See what there is. Consider how you approach it. Just about everything is on youtube on film, USE ONLY good and suitable tools. Our advertisers have it and good tools do not have to cost any capital.
