My 06 ds650 x gets stuck in gear. The shifter moves up and down but is not engaging. After a few bumps it will shift again. Usually gets stuck in fifth but occasionally will not go from second to third without much persistance. It looks like a total teardown to repair. Any similiar experiences?

 

That sounds like it may be the shift fork being your problem. And yes, you would have a major project there. Got to split the cases.... But you can get your tranny gears backcut, and fly wheel lightened while you are in there..... Good things to have done...

 

Do a search on "shift fork" "shifting problems" or "popping out of gear". This has been an occasional problem with the DS 650, but usually on 00 01 02 and some 03's. After that, they supposedly upgraded the shift forks. Expensive to fix if this is what your problem is, as the cases have to be split. There is a guy on here, Hightower I believe, that did a very good step by step with pictures on how to do the shift fork replacement, if you are so inclined. Are you sure your clutch is adjusted correctly, and that its not slipping?

 

It definately sounds like shift forks but could possibly be a bad engagement dog on your second gear.

I just finished replacing mine since I had it out of the bike already even though they didn't need it. It wasn't a hard job but you need some special tools (flywheel puller and a torque wrench to put it back together) and an open mind. I had some problems with the spacers on the transmission shafts when I put everything back together but no big problems. I believe Bombardier updated the forks in 2003.

I have my shift forks and shafts on eBay right now. You might be able to pick them up for a deal. My new ones cost $170 for everything. Let me know if I can help. [img]i/expressions/beer.gif[/img]

 

it may also be the shift shaft. its all in there to gether. bike bandit had all the parts and were pretty cheep too. shipping was within a week or so.

 

Thanks to all. Will start wrenching next week.

 

O.K. Got it down to the Magneto. Neew the Magneto puller p/n 529-035-748 and crankshaft protector p/n 420 876 557. Where can I find them for sale?

 

<div class="FTQUOTE"><begin quote>Originally posted by: Cessna

O.K. Got it down to the Magneto. Neew the Magneto puller p/n 529-035-748 and crankshaft protector p/n 420 876 557. Where can I find them for sale?</end quote></div>

Motion Pro used to sell them, thats where I got mine, don't know if they still do but try em.

 

Thanks again, love this forum! Ordered the tools from Motion Pro and parts from bike bandit today.