Hi Guys,
Looking for a little input if possible. My zilla wouldn't stay in 4th and had no 5th at all so I tore it down and the #3 shift fork was ground to a nub. I replaced the fork and checked and cleaned everything according to the shop manual. Even though I shifted through all the gears when disassembled now it jumps out of 5th when any torque at all is applied. I have resigned myself to another tear down but I don't know what to check that I haven't already. Any ideas would be very welcome. I drained the oil and had little to no metal in it and the other gears shift fine.

 

well im fighting the same thing olny second gear . i figured mine out . look at the shift drum for any wear . also look at the ears on the gears . if they are rounded .. they need to be replaced . also the little prawls at the end of the shift drum are prone to fatigeing . replace them and the little springs and pins in there . they are cheap and easly over looked . also the spring that holds the shift drum slide arm in place can get week and not hold . i would replace it also . the next thing to look at is the spacers (washers) and snap rings . if any are loose that is a definite replace .

hope my novel gives you some stuff to look for . i did alot of reseach on it so you asked at the right time .

Don

 

Thanks thats exactly the info I needed. I checked the spacers and clips but not the pawls and springs you mentioned. You probably know better than I what a big job it is to get in there. I can't wait to do it again. As often as I use 5th I may ride awhile until it gets eating at me enough to tackle it.
Thanks again !