one thing you can try is to run it through the gears by hand, it may bind a little bit when you hit the broken teeth but should turn through. When it binds up real good see what gear is engaged (sliding gear has locked into it) the gears its locked into may be the problem.

Also check the shiftforks to see if your theory of being in 2 gears at once may be right.

Maybe a list of what you replaced might help also. Shift fork 1 does not necesarily need replaced but should be since its probably week, shift fork 2 must be replaced and shift fork 3 is ok.

 

The weird thing is that it goes through all the gears by hand and when it was together, and everything checks out fine. When i first rode it i took it easy and went through all the gears down the steet. Everything worked great so i went about 3/4 throttle through the gears and thats when it happened. I think it is a defect gear. I also put a 11:1 piston, wb cam, and yamaha clutch kit in. Could all that plus the total traction i was getting on the street be enough load to sheer those gears?

 

I would think if the gear were that fragile it would have lost more teeth or shattered all together, did it lock up? or just bang, click click click? It should be able to handle the road without any problem! thats where I tested mine also.

Do the teeth on those 2 gears fully mesh with each other when installed?

Im not sure how far you are from me in Eastern PA, but I would llike to look at it if you want. Im about 35 minutes up the PA turnpike from NJ

 

How much oil was in the engine after assembly? THanks for posting the pics 007. Raptorsp500....you were in 5th when it locked up...right?
Wait a minute....I only see 2 dogs...and based on the spacing the last dog is on the backside of our view for 2nd gear main drive. It's an 01.

 

I poured some oil into the crankcase before i sealed it up and i filled the tank with the rest. Before I rode i checked the oil and filled it.
The engine didn't lock up, when i slowed down for the corner i heard the engine making a knocking sound, so i rode it home in 1st gear. When i took it apart i found the gears like that. They mesh just like the rest of the gears.
gary - I checked and the gears are 02. There are 4 dogs on 2nd.

 

did you do the work yourself or was it done by a dealer?

 

I did it myself.

 

so is your problem fixed, can you still ride it, or what?

 

Well I have to order the gears from the dealer on tuesday, 2nd day air so i'll get them on thursday and have it back together for the weekend.

 

well good luck, I just had 02' gears put in mine, so hope everything works out okay. I am going to pick it up tomarrow. Did you do a break in for your new gears??