Wondering if anyone else out there may have had this problem? Second gear is slipping bad can't keep it in gear it slips then will pop into neutral. At first i thought it was the clutch but every other gear is fine. Had a couple buddy ride it all saying the same thing 2nd is gone. The bike is only about 7 months old ( just out of the 6 month warranty ) I got the extended but they probably tell me its void because I have exhaust or some crap like that. Any suggestions? Thanks

 

BENT shifting fork!!![img]i/expressions/face-icon-small-disgusted.gif[/img]

Dont ride it any more!!! you will cause damage to the gear its self. The cases will have to be split to change the shifting forks, so I would definatley take it to the dealer, and RISE HELL!! I f you give them a way out , they will take it, so demand satifaction.






Biggerisbetter.

 

What Bigger Said.

The new shifting forks look to be of a harder metal (I think they are all black with kind of a matte finish now??? Can't remember.)

While you are in there you may want to send off the gears to get undercut. (Actually, the engagement dogs.)

Take a close look at the engagment dogs, if they are shiny or worn you will want to replace them or replace them and get them undercut. If they aren't warn (as mine weren't) you may want to get them undercut. I didn't get the undercut done because I didn't want to wait and miss a trip but, next time I am in there I will do it (cost is about $200) Check these guys out MRE

Oops, that isn't the right link. Can't find it. Do a search on undercutting gears etc. and you should find a link to a guy in NY that does the gear undercutting. Some have also done cryo treatment too.

 

MRE , Under cut my dogs on my gears, and they seem to be working well, alittle sticky between 1st and 2nd, but other wise works fine. They did take thier sweet time with them so , I would suggest calling them every other day to keep them motivated.[img]i/expressions/face-icon-small-wink.gif[/img]






Biggerisbetter.

 

Thanks
I’m think I am going to try and do what biggerisbetter first suggested and try and get the dealership to take care of it. If they don’t I am definitely canceling my extended warranty as this type of stuff is the reason I bought it.

What exactly does the under cutting do?
I haven't heard about that.

 

Undercutting the engagement dogs (they are already slightly undercut) keep them together.

Don't have a picture so best I can do is show it this way ("L" is the left gear "R" is the right gear and the "-" is the engagement dog) - the formatting won't let me do what I want so, immagine all the "-" and the "<", ">" are directly above and below eachother:
Stock:
L-
-R
L-
-R
L-
-R

After undercutting ("< & >" are the engagement dogs):
L<
>R
L<
>R
L<
>R
L<
>R

As the L wants to move down and the R wants to move up on the screen the undercutting forces them to stay engaged (the L and R together). Currently what is happening to you is your shifting fork is bent (the fork is between the "-" , but above it in a kinda grooved opening). Since it is bent, it isn't allowing the dogs to come together sufficiently to engage completely and they are popping out under strain.

I am sure all this would make sense if you knew what I was talking about [img]i/expressions/face-icon-small-wink.gif[/img] (but, then you wouldn't need it!) [img]i/expressions/face-icon-small-happy.gif[/img]

If you get it covered by your extended warranty, tell the dealer you want to pay to have the gears undercut and you will send them off for the work. That way you won't have to worry about it again. Oh, and don't push too hard on the shifter - Getting mad at the tranny for letting it pop out of gear won't help anything.

 

Thanks for all your help.

The dealer is telling me I am looking at around $1,500 to get this taken care of if the warranty doesnt take care of it ( they have to send an ajuster to look at it after its torn apart )

Is this moderately capable mechanic type stuff or advanced/specialty technician?

 

That price is too high (unless he is talking about replacing your entire tranny!)

I would say this is moderately advanced.

We have a guy up here that would do the tear-down and re-assembly of the engine for about $300-$500. (You would have to pull the engine out of your quad for him though. Shift fork was either $40 or $70 (only the 2nd gear one is bad.) At the most you need two new gears (the ones the dogs are warn on.) How long have you been riding it like this? How much metal in your plug when you change the oil?

The dealer charges are typical for a dealer.

If you are going that far you might as well throw in a high compression piston and cams. (You have to replace the gaskets anyways.)

Send me an e-mial and I'll give you my number. Maybe we can help.

mjbeaty@worldnet.att.net

 

Your dealer is trying to scare you OFF![img]i/expressions/face-icon-small-mad.gif[/img] How and the heck is an "adjuster" supposed to know what the he!! he is looking at??? before he will OK your claim!! BULLCRAP! you tell him that your payed for EXTRA warranty because of something JUST LIKE THIS MAY HAPPEN. and you want the problem fixed, and if he still acts like he wont, demand to talk to his Bomb representitive!!! Tell him to ride it,and when it pops out then hell know. It sucks to be a nice guy now days! if you remian dignified and rational, the daelers will walk all over you!!SOB's!!

But if you go in thier screaming,and ready to fight, then you get your stuff for free,and everything starts rolling along fine. WHY IS THIS???



You will have to threaten your dealer to SUE or something to get this done, and it will be worth it, cause this is HIS responibility as a dealer to make it right. ou dont want to do this job if you dont have to, and you shouldn't!! I had to , and I was a nervous wreck, Luckily I had DSmike to help me. but I assembled it by myself at home, and I wore alot of these guys SMOOOTH out with questions,and questons, but with thier patience, I was able to do it.

Good Luck! and please dont let your dealer stick it in you!






Bigger.

 

Seemed high to me also but it was just an estimate he wasnt sure on the price of the parts or what would need to be replaced.

as far as how long i rode on it I rode it for maybe 1-2 hours after i started experiencing the problem first it started small
then got worse. I changed the oil because I first thought it was a clutch slippage problem. I didnt see any metal but i dont have
a maganet on my drain plug ( it was replaced with a taller one do to the old one stripping ).