shift forks or shift shaft, you will have to split the cases to fix it... get a shop service manual & read up on it ... its not that hard to fix & it will save you a ton of $$ . if you let this go it could cost much more to fix in the end. i was nervous when i split my cases but it was not a big deal just take your time & follow the instructions.

 

I agree as well - I was scared _ _ _ _less when I split the cases myself, but it was not the hard.

There are lots of good direstions and pictures on here.

When are you heading to Idaho ???

 

I am not really worried about splitting the cases, it is more the time issue and missing trips.

We are heading to St. Anthony's the 3rd week in June.

 

bikebandit.com has all the OEM parts and were VERY quick to ship mine. i had my stuff within 1 week. took it apart on saturday and had my stuff for the following week end.

 

JMann that sucks, sounds like you covered your bases on the clutch to rule it out, the only other suggestion I have is how is your idle speed? I ask because if idle is set too high it makes it more difficult to shift into any gear, thereby increasing the chance of not quite getting it shifted all the way in to good gear dog engagement.

As far as reving to 9K on occasion, don't worry about it, I did it alot over the years even before I had the updated valve springs for my cams and all that, and it never hurt a thing. the stock motor can handle the occasional over rev, it just aint making much power up there. I've been running the RWR cdi for about 6 years now...and still running on OEM '01 model year shifting forks too, I've never had a tranny issue and my cases have never been apart. I attribute alot of the reliability to using the clutch for what it is meant to do and I don't speed shift in drags, I clutch for every upshift. Winning a couple extra races aint worth a tranny rebuild to me. But I do down shfit without clutching, providing I'm not under load.

 

Glad to hear that the quick 9K rev isn't really hurting anything, that was a big concern I had. As for idle speed, I try to stick it around 1300 average. I only powershifted when I first got it a few times, ever since I have used the clutch, even downshifting.

 

well darnit man, sounds like you've ruled out all the little obvious stuff, tranny tear down may be the next step,
go to the DS links link in my sig and you will find a link there that has the most detailed and picture orientated tranny rebuild segment on the www.

Good luck!