just rebuilt the 230S and when I shift to 4th gear and start raising the RPMs it slips out of gear. Then I pull in the clutch and upshift and it goes back in gear. what is going on ?

 

did you measure the shift forks and grooves in the gears for wear? or did this just happen after you rebuilt it and before it shifted fine?

 

yeah I took 2 engines and made one, but it shifted fine when we first built it. I haven't taken it out yet, but I was in the yard just cruisin' trying to let everything conform together ( before I get 4 miles out on trails) and 1st - 3rd went fine but when I get to 4th and get on it a little it just pops right out then I up shift and it goes again like nothing ever happened. should I check the forks ? I would think it would slip out through all the gears but I guess it is possible. any info would be great I have no idea where to start I built this thing from the ground up and ripping it all back down would just.......... well you know !

 

yes it will shift fine on the bench but when you put a load on the tranny it will cause them to slip. the fourth gear must have worn dogs or the mating gear wear the dogs engage could be worn. its more likely the gears if you can put it in but when you get going it pops out of gear. i had a 95 yz 80 that did the same thing shifts fine when on the bench but when you get any kind of load on it it slips, found out the gears were worn.

i know its a pain to pull an engine apart right after you built it up, been there before. guess your only going to have a 3 speed instead of a 5.

 

so let me get this straight I need to rip it down and your guess would be to replace the 4th gear itself. I guess the best thing to do is while I'm there I should go ahead and replace the gear and the mating gear. you said "been there done that" so would you know if I were to go ahead and buy all five new gears about how much would they cost ? NEW not ebay. by the way thanks alot for your help I guess I kind of knew this in the back of my mind but I didn't want to grip reality, I just needed someone else's opinion before undoing all that work.


-- gone to get the tool box back out ---

 

i've never personally had that problem with a lt230 but i've had to take engines apart right after i finished them up because i missed something like your problem. that 80 i had i pulled it apart 3 times before i broke down and bought the new gears. thats why now i check everything before i put anything together.

if you replace 4th gear plus the mating gear that should fix the problem, but make sure to inspect all the gears before you just go and buy 2 gears. the gears i would guess brand new would be from $40 to $70 a piece. and theres not just 5 gears theres 5 more mating gears equalling 10. thats alot of dough for a new transmision.

before you buy anything this is what i would do, tear it apart again, pull of the gears and check them all out good. look at the dogs and wear the dogs engage. then measure the forks and the gears they ride to make sure there within specs. after you do this you should find something thats out of spec.

 

when my second gear went out it was the gear dogs,the little notches on the sides of the gears that go into eachother,i would dissasemble it,i would check for obvious things first,then start measuring the forks and stuff if nothing is obvious,when my second gear was out,it was very obvious when i opened it up what was causing it