Was at the dealer today picking up parts and a guy came in to get some parts. We get to talking and his tranny is popping out of gear from 1st to 2nd gear.

Anyways, for those that may not have seen this information before (I know we have new people come on here) the 2000 through some of the 2003 (I think, may have been 2002) had a softer shift fork. If the shift fork bends, it hangs up the tranny where the engagement dogs won't grab. If this is happening on your quad, get the shift forks replaced.

While you are in there, look at the engagement dogs to see if they are rounded off. If they are you may be able to get them undercut or you may have to replace them.
If they are not rounded off, you may still want to get them undercut.

I think This is who I had do the undercutting on mine.

Undercutting cost is about $350 if I remember right. They also Magnaflux the tranny (check for cracks) before they do any work on it.

Some people alsy Cryo treat the tranny and shift forks for added strength. I didn't and don't think I needed to with the new shift forks.

Anyways, this is something a few people have run into on some of the earlier models.

Oh, if you split the cases for any other work, you may want to go ahead and do this work. At a minimum replace your shift forks. They are about $50 each. Also, not a bad idea to replace the shift shaft.

 

how many people have had this issue? I've heard of it here and there, but sure haven't had any problems with my '01. I bought it new and have ridden the holy crap out of it all over this beautiful country from one side to the other. has anyone linked it to shifting habits by chance? like I always use the clutch when upshifting, never use the clutch downshifting. when I first got the bike I immediately realized it does not respond to clutchless upshifts like a honda, so I stopped doing it right away.

 

I've only herd of a few cases. I don't think it's a problem with all DS's. Prolly just those of us that are REAL hard on them. Power shifting, hammering the shifter while at the line, Hard on the shifter when landing a jump, etc. [img]i/expressions/face-icon-small-sad.gif[/img] Ya know all the stuff you should not subject a tranny too. [img]i/expressions/face-icon-small-wink.gif[/img]

What DuneMe has said does seem to be the fix for those of us that have had the problem though.

 

[img]i/expressions/face-icon-small-confused.gif[/img] Seems like maybe hill-shooters are more prone [img]i/expressions/face-icon-small-confused.gif[/img][img]i/expressions/face-icon-small-confused.gif[/img]

 

Eagelcollector that's a real ncie fork replacement guide you've got there!

 

Thanks Hightower. Hopefully not to many will need to refer to it. But if they do it should help them get through it.

 

i just had an incident that sounded like the tranny busted. I split the case lastnight to find no broken anything. All was fine, but one shift fork is ground into, and is .060" bent as compaired to the new ones. The other 2 were .020" bent as compaired to new.

Thing that surprised me, the shifter dogs are backcut allready!? I got it used last year (2000ds) and neutral was hard to find then, and it didnt shift the smouthest either.

So can someone please tell me; did they ever come factory with backutting? Or did this guy have major problems with his shifting foot and have it done allready? They are definatly back cut. But the forks were definatly bent as well.....

Should be back together this weekend for a ride to see if it made a differance.

Dave.

 

Here a picture of the new fork and the bad one that was bent so bad it ground against the gear.


Other then the scrape, it visually did not look bent! You have to measure and compare to a new one to to tell it was bent.

Here is a picture of the forks. (picture works now..) left=new / right=bad

My web site has limmited access, so it my be unavailable if it get to much traffic each hour. Try later if you wnat to see the pic....

Dave...