I noticed my bike finding a false neutral last month at Little Sahara once or twice and then this past weekend it happened four times at Silver Lake... everytime I was riding it hard would go to shift to 5th and it would rev to 9K till I could pull the clutch in, put it into 5th for sure and go. I think it happened once going to 4th too. Is this the shift forks? My quad is an 04 so it should have the updated ones, but then I found this post by MR.HP:

http://forums.atvconnection.com/mess...=shift%20forks
This sucks, I am going have a Silver Lake trip planned in 2 weeks, Allegheny Forest for Memorial Day, and our big trip to St. Anthony 3 weeks after...
[img]i/expressions/face-icon-small-mad.gif[/img]

 

 

Generally the shift forks go between 1st and 2nd gear. The forks start to get wear on them then hang-up and don't allow the engagement dogs to fully engage.

So, I'm not sure why this is occuring. . . I guess it could be shift forks, just hate to see you go that far if it isn't.

IF you do go into the engine, I would suggest having the tranny back-cut. Don't want to spend the money going that far and then have the issue again. . . I know it is added cost but, that's just my thoughts. . .

 

hmm, wonder what would cause this false neutral issue between 4th and 5th...

another question, when this happens it hits 9K rpms pretty quick, I have the Woods cdi so no rev limiter... is this hurting my engine, if so, how much?

 

I agree with Dune Me. As well when my shift forks started to act up I had trouble getting it into the lower gears, don't believe i had trouble with the higher gears.

If you do go in, get the tranny gears back cut, it makes the tranny shift so nice, I never hit netual or miss a shift anymore.

I know it might seem like a silly thing but have you tried to tighten up the clutch cable a bit and see what that does???

 

It doesn't like to go in first at all unless I am stopped and sometimes when I try to put it in you can hears some gears rolling.

I have adjusted the clutch cable all over, even re-indexed the clutch arm on the case, more free play, less, not a clutch adjustment issue I don't think. I just put in a new oem clutch and have 60% woods springs. I took the cover off and triple checked, so I know everything is good there. Has to be a tranny issue, just not sure how bad.

I am really worried about the RPM's shooting up, maybe I will pick up a Vortex cdi so I have a rev limiter. I just don't want to put off splitting the cases and then the bike break down the first day in Idaho after a 30 hour drive. That would suck.

 

i had a similar problem & it ended being the shift shaft was bent REALLY BAD. i thought it was the forks as well. they were fine , i have an 05. just my 2 cents

 

Do you have to split the cases to fix this?

 

Also could be your clutch. I know you put 60% springs in there with a new oem clutch, but it could be slipping. I haven't seen any shift fork problems on 04's and later, I think they are not as common. Since it is happening in higher gears, My clutch done the same thing. Even with 60% springs. Just a thought.

 

When my forks were bent it popped out of 4th cost me 2000 to fix. Hit the valves, ruined a brand new piston, trashed the cylinder and head. Fix it!!!!!!!!! Don't chance it.