Has anyone had their 400ex slip / pop out of 3rd gear and then pop back into gear immediately. Mine does it all the time while in 3rd gear and under load. That is the ONLY gear it does this in.
I was thinking maybe a bent shift fork. But shift forks usually handle more than one gear.
Could it be the shift dogs on the gear? If you had a similar problem what was it?
Thanks all...

 

i had the same problem with my suzuki quadsport 230s i replaced the clutch disks an it was fine

 

hondahero53...thanks bro. That is the first thing I tried. I put a new White Bro's clutch kit in it. That part works great. A little stiffer clutch pull but nothing like my DS was before I put the magura clutch kit on it.
I think it's the shift dogs on 3rd gear or whatever gear it mates with. I was hoping someone else had a similar/same problem and could shed some light on weather that was the culprit. I would hate to split the cases and find out that I didn't need to. [img]i/expressions/face-icon-small-wink.gif[/img]

 

i have the EXACT same problem, but it only does it on occasion....

v581

 

are you sure it isn't the chain skipping or binding a bit?

 

The chain deff. needs to be replaced. But I would think that would be a problem in all gears expecially the lower gears when your under a harder load. But it only happens in 3rd. And only when on the throttle.

 

mine did that when it was bone stock. it was even brand new. it did it in 4th though and only at higher rpms. i tightened the chain a bit and it didn't do it nearly as much. now that i am running aftermarket sprockets and a DID X-ring chain, it never does it. just a thought....

 

Mine occasionally after I shift into third, dumps itself back into second, which usually is a good thing because I probably should have been in 2nd anyways, but its still a little odd.

 

take off your right side clutch cover, i think youll need to remove the brake and maybe the exhaust. look at the star behind the clutch basket. check to see if any of its points are broken or worn and see if the roller is going into the correct place in between the points.

 

Well, It deff is in very bad need of a new chain and since I have to replace that anyway. I think i'll just do that and and see what happens. Maybe i'll get lucky for a change and not have to tear into a another motor this month. Thats a snide remark aginst my DS...[img]i/expressions/face-icon-small-wink.gif[/img]