Ok guys, here's the deal. I'll do my best to explain this fully so bear with me.

My buddy has a DS that has been having some problems.

Basically, he was riding one day and he heard this "Pop" and it appeared to be slipping the clutch. I took a look at it and found that the little deal (the one with all the teeth) that pulls the pressure plate away from the clutches had a broken tooth. I fixed that and put it back together.

Then he took it out again. Same problem with the "Slipping clutch" even though everything was adjusted right.

Sooo... We did a little measuring and found that the clutch plates were a little on the thin side so we went ahead and replaced the clutch.

Anyhow, a couple of days ago he took it out again and he said that it was having the same issue in 2nd gear. Slipping clutch symptoms. Before too long it went bang and it punched a hole in the top of the gearbox just above the output shaft. I can look in there and it appears that the shift fork broke, which I'm assuming ended up going through the case.

Has anyone had issues with shift forks breaking?? I don't know what to think about this but it's gotta come apart now regardless.

Are there any "Gotta have" mods that we can do while we have it all torn down that will make a decent difference in power and so on?? Keep in mind that my buddy is cheap!!

Any feedback is appreciated.

Thanks!!

 

if it was me and i had to rip my tranny apart i would get the gears undercut, i have read a few posts about that on here not much for making hp but it will make it buttery smooth

 

Yes... the first time around for me It was poping out of second gear under extreem load. Finally it just busted one of the sift forks and took out 2 gears. (Actually 3 but I only thought 2). Didn't go through he case like your buddy's though. Sorry to hear that. Any way...all was fine for a while then it started doing it again. Even with the upgraded shift forks. Tore her down again and thats when I discovered the other fractured gear. Then all was OK again for a while and now she's back to her old tricks again. I bought another tranny and sent it off to get the gears back cut. Soon as it done i'll be swapping trannys. Since your gonna bve in their I would replace all the shift forks, shift fork shafts, All damaged gears and have them back cut. Take a real close look at the groves in the Shift star. Also the shift shaft at the spring end has kinda like a rivet in it. Not really but kinda...any way check that and make sure it has no play in it at all. If it does replace that also.

Gotta have mods since you got it apart.
Piston $350 and up
cams $260 and up
CDI $250 and up
If you still wnat to spend money
Send the head off for port work and bigger valves $$$$$$$$$
Since you did that ya gotta have a carb maybe two[img]i/expressions/face-icon-small-wink.gif[/img]
ETC...ETC...$$$$$

Good luck
Ya know it really is fun but very expensive[img]i/expressions/face-icon-small-shocked.gif[/img]

 

Eaglecollector:

Who's doing your undercutting / backcutting?

I sent mine off a few weeks back and just spoke with my guy today. I had some cancer on my third gear. Was able to pick up a slightly used tranny so I went ahead and sent it to him. I'm going to have the new tranny undercut and then kryo treat this one.

Undercutting will actually make your tranny a slight bit more knotchy but, the angle on the engagement dogs helps bring the gears together when you want them there.

Do a search for undercutting and for tranny and Transmission and you should find more information.

As for your question about weather this has happened before. I haven't heard of this but, the 2000 - 2003 DS's had a different shift fork than the ones you currently get from Bomb. The new ones are dark and the old ones were light (shiny look - chrome like finish.) If it is a 2000 or 2001 and it has been popping out of second gear under load for a while it could have been warn to where he hit it to shift it and it just broke (seems unlikely though.)

As for the clutch teeth breaking. Unfortunately, this is more common.

If you want real power talk to Falicon about a stroker for the crank while it is out but, this is a few $$'s.

Pami offers a couple strokers - talk to the Bom
Mr. HP and TVI both work with Falicon to offer stroker engines with bigger bores.

All are bigger bucks but, unbelievable power.

 

DuneMe
Im not sure exactly who is doing the actual work...But I sent the other tranny that I had off to Eric (MrHp) and he is having it done. Should be here any day now. I was actually hoping that I would get it back in time for T-Day but that isn't gonna happen now. Even if it showed up tomorrow I wouldn't tear into it. Im shooting for New Years now with a new tranny and Big Bore[img]i/expressions/face-icon-small-happy.gif[/img]