I have a 2002 Honda ForemanES that my dad let me have to use around my house. He bought this thing with 1200 miles on it. Now 13 months later, it's got 6500 miles on it. 6500!!!!!!!!!!!! He rides alot! The problem is that it jumps out of 3rd gear. I've had it apart 3 times. 1st time, I changed the shift fork because it was bent. 2nd time the fork and gears on each side of the fork, and fork sleeve. Then the fork again. He finally got tired of spending on it( front and rear brakes, swingarm bearings,etc....)he bought a new suzuki. I would really like to get this thing to stay in 3rd gear but don't know what else could cause this thing to bend the shift fork. He was climbing a hill with it in 2nd gear. It rolled to the bottom and when he got it out of the tree it was stuck in 10' in the air he saw it was in 3rd gear. Since then we've had to change the axle because the teeth stripped out where it goes through the ring gear, u-joint and drive shaft in the swingarm, etc. Needless to say he's hard on things. If it was in 2nd gear going up the hill and got changed to 3rd what could've gotten bent? The fork runs in a sleeve with teeth on each side. These teeth were wore off so I changed all these gears except for 3rd because it was discontinued. So I had a machinist build the teeth back up. What would be bending the shift fork though?

 

Who told you 3rd gear was discontinued ..

 

Worth Honda in mount airy.