When i first got my quad it would pop out of second gear,wouldnt stay in at all.I have split the cases as of tonight.But the thing is,both second gears look fine,or at least every bit as good as the other gears wich work fine.The only thing i can find that seems fishy is that the bearings on the right hand side for the trans shafts have a little play in them. Would just that play in the bearings on the right be enough make second gear not work.It will shift into second,but it pops right out. ive bought trans gears/shafts from a 90',and they look just like the ones i have. question 2:The bearing on the left hand side of the trans shaft,the one that you put the main drive sprocket onto,seems tight,like its pushed against the oil seal.i figured this is probably normal,cause its against the oil seal.it turns smooth,but like the oil seal is pushed against it.should it be?

 

Check your shift forks. Make sure they are still the spec'd thickness and don't show signs of uneven wear.

 

The shift forks dont look to bad,with the used trans parts i bought,the shift forks from it look ok,only one of them has a tad bit of uneven wear on one side of it,but they dont look any better than the ones i already had. Could spring problems cause it just to slip outof second?

 

I've always heard that jumping out of gear is an indication that the shift forks or drum are bad. When I rebuilt my LT, my forks had a little bit of wear and I had never had any problems, but the mechanic recommended I replace them so I did.

 

was the returnspring still hooked up to the pin? or are the dogs on the gear rounded. alot of people look at the gears but not the dogs. if the dogs are rounded there gone and will pop out of gear.you need to check thickness of shift forks not they look like the other ones maybe those suck to? take them to somewhone who can measure the thickness otherwise just replace them there not that much and you will be happier with the results anyways.

 

i think i found the problem,on the larger second gear,i cant remember if its the main shaft or secondary,not on the gear dogs,but where the gear dogs go into the big second gear,the gear is really rounded and screwed up.that has to be it.That gear combined with 17 year old shift forks,and bad bearings has to be it.your thoughts?

 

On the inside of the gears there are nice squared off edges where the sliders engage them. When the edges get rounded off the sliders wont engage them well enough and they pop back out. I just finished putting $400 worth of gears into an 87 Zilla last week. It wouldnt stay in 2nd and would pop from 4th to 5th by itself. Also if you see any unusual wear at all on the shift forks then replace them. And I would not even ever tear into a Suzuki without replacing the detent spring. That's trouble waiting to happen. The Zilla works perfect now.

 

the first gear looks marginal,i might replace it,but it worked fine before i tore it down,but that second gear is definitely screwed