i was cruising @ about 40 mph and went to downshift when the light turned yellow. when i hit the shifter down, the gear didnt engage, but rather felt like it fell in between gears. i felt (and heard) the teeth chattering erratically as i continued to pull in the clutch and attempt to bang the shifter into 5. so there i am, coasting across a red light intersection at a neck-breaking 37 mph, motor revving and gears grinding. i pulled to a stop, finally got the tranny to shift, got a false neutral, continued to downshift, then everything was in order. 5 mins later, the chatter came back, and as i shifted into 2nd, the tranny clunked, the rear tire chirped, and the motor now sounds like there is a rock bouncing around in the crankcase/transmission area at idle in neutral. if i put it into gear, the sound pretty much goes away, but comes back as soon as i accellerate. now, my question... has anybody experienced similar problems? does anybody know what it could be? the bike is stripped down and ready for the motor to drop out for repair or replacement, so if somebody could help me in one direction or the other, it would be GREATLY appreciated. by the way, i already checked the throw-out bearing and it is fine. sorry for the long-winded story, but i figured the more info i could give up front, the quicker and easier i can find a resolution. thanks!

 

123456

 

I Havent Had Any Tranny Problems With Mine But I Went Through 3 Transmissions On My 900rr. Sounds Like You May Have Chipped A Piece Off Of A Shift Fork. Make Sure You Replace All The Parts Or Youll Have To Do It Again. I Have A Good Tranny If You Get It Apart And Dont Want To Spend 800 On Parts Alone. Could Be A Clutch Problem Too, Take The Motor Apart, Im Curious.

 

Hey man,
I have had about 50 transmissions apart and I would bet you have a detent arm issue.

That is what created the false nuteral. there is a bolt that holds the detent arm tight so it can spin the shifter drum/ move shift forks/change gears etc..

Pull the motor out. take your injection system off drain and flip the motor. pull apart at the lower case. the gears stay w the upper case andlower case w the shift forks comes out as one piece so you can mess w it. More than likely what happend is that the detent arm came loose and causes the whole thing to get out of wack b/c it cant spin the shifter drum and than you tried to force it in to gear and you have damged the star on the end of the drum where the detent arm spins it....could have broken a piece of the detent arm off possibly also and thats the noise.

Don't worry it's an easy fix..... you will need to pull it apart and get a new detent arm shifter drum and maybe shift forks if they were bent ( not likely they are tough) and you will need some gasket maker. make sure to razor off all the old gasket material b/f you seal her back up. get it real clean. lay a super thin layer on the upper case and go around each bolt hole w a circle. let stand for about 30 min and then mate your two cases. It will only go back in and fit one way so just drop in the shifter forks in the slots and the gear assembly. if it goes together its in right.

hope that helps.

 

so heres the deal.... the shift drum snapped between the left and center forks and ended up dropping a chunk into the tranny that ended up bouncing around until it got caught in between gears and began snapping teeth. so i found a bit of shavings, a chunk of pot metal from the drum, and about 5 gear teeth, there in the lower case. FUN FUN FUN!!! now onto recovery.....