It rears it's ugly head again.
 

C'mon guys, help me out here.[img]i/expressions/face-icon-small-confused.gif[/img] The problem I had a couple of months ago has returned.[img]i/expressions/face-icon-small-sad.gif[/img]
Thanks go out to BigDaddy and Vegas for the parts, in a hurry and at an affordable cost.[img]i/expressions/face-icon-small-wink.gif[/img]

Since I replaced the clutch plates and the springs due to what we thought was the clutch slipping I have made a couple of trips each to Dumont and Glamis. The problem I was having at Glamis is still there. Doesn't duplicate itself at Dumont, well, maybe once or twice, but often at Glamis.
Here's the deal, going from third to fourth, the transmission doesn't seem to click (lock) into gear. Does the same thing on ocassion from fourth to fifth. Every once in awhile the shift lever sticks and will not allow me to shift down. Pretty often, while in neutral I start to hear some rolling and the bike will drop into gear.[img]i/expressions/face-icon-small-shocked.gif[/img] When I replaced the plates, the ones I put in didn't look much different than the ones I took out so I'm thinking they were not the problem.[img]i/expressions/face-icon-small-disgusted.gif[/img]

So, having said all of that, SHIFT FORKS???[img]i/expressions/face-icon-small-blush.gif[/img]

It rears it's ugly head again.
 

Sounds like the shift forks are bent to me. Is it popping out of gear will it just not go into the next gear? This might sound a liitle dumb but ive had it happen. Is the shift lever bent and hanging up on the side of the motor?

It rears it's ugly head again.
 

Scatterbrain is unfortunately.... probably right.

It rears it's ugly head again.
 

Not popping out, just won't go in sometimes, like missing a shift but I'm going through the whole motion and paying particular attention to it as to ensure I am going up all the way. With my size 15 it's not too hard to get the lever all the way up.[img]i/expressions/face-icon-small-wink.gif[/img] Not sticking on the case either, first thing I checked when it started happening awhile back. I wish it was that simple.[img]i/expressions/face-icon-small-disgusted.gif[/img]

Is the sand at Glamis really that much different that it would put so much more of a load on the forks? Or is that even how it would work?[img]i/expressions/face-icon-small-confused.gif[/img]

Am I to assume that all three forks need replaced and just order all at once? From the looks of the links I pulled up this may take a little longer than the 30 minutes the clutch replacement took![img]i/expressions/face-icon-small-shocked.gif[/img] I'm open to any and all input at this point in time. What causes this problem? I use the clutch everytime I shift, no speed shifting. What about "popping" the clutch?

Anything else I need to order besides forks and the case gasket?

It rears it's ugly head again.
 

Vic,

Let me know when you tear into that thing, if I can maybe I'll come out there and help ya. It might be an amusing day project and I'm interested to see what the inside of the tranny looks like.

It rears it's ugly head again.
 

Well, from all of the research and studying I've done I'm just not sure that "amusing" would quite describe anything associated with doing the shift forks.
I will keep you posted though. I think we should gather a bunch of DS bubbas around the trailer, glasses of Apple Pie in hand, and rip into this thing! Good learning experience for everyone involved. Looks like all of the Big Dogs are out at the dunes this weekend, still waiting on a couple of answers from their likes.
I'd be out there with them but here in about two hours I will be pretty occupied, with the green flag dropping and all...

It rears it's ugly head again.
 

I'll try this one more time since it looks like everyone is back from the holiday.[img]i/expressions/face-icon-small-smile.gif[/img]
My original question was what all items will I need to order to get started?
Is anybody sure, that with the symptoms I'm having, that it is in fact the shift forks?
Why primarily in Glamis?
What bends them? I do use the clutch every time I shift.

Thanks guys.

It rears it's ugly head again.
 

Coincidence.....

Why someone would indicate it was clutch plates is beyond me. There is no question in my mind that it is a trans problem, most likely shift forks.

I would carefully read through a service manual and a parts catalog to identify areas where the problems could come from.

I'm sure some of the builders here could better identify the source of you problem but I don't believe the differences in altitude or sand at Glamis or Dumont have anything to do with why you have a shifting problem its just a coincidence.....

It rears it's ugly head again.
 

By the way....If you need help and the timing is right I could come out your way and help.....