I have a 88' Quad Racer 500. It pops out of 2nd gear when the rpms get up. I have torn it down, the only problem I see is the gear shift rod is baddly bent. The gears all look good, no chips anywhere. The forks look good and the gear cam looks good. Any ideas?

 

I have the same problem I just rebuilt my motor also. Does yours vibrate extremly bad mine vibrates so bad I have bolts falling out everywhere. My Zilla is a 90

 

Mine does vibrate pretty good. Loctite is a must on this machine. I talked to a few people today about the 2nd gear problem. They say I need to replace the fork and 2nd driven gear and 4th driven gear.