06 popping out of 5th gear

[mtrdrms]

Hey guys. Havent posted in a while mainly because the bike has been perfect...until now. Let me preface by saying this bike gets used and used pretty hard. It has seen many supermoto track days, harescrambles, and most recently, wide open ice racing. However on my last trip to the ice, it was popping out of fifth gear (wildly inconvenient during a not-so-friendly, my-bike-is-better-than-yours, battle with a CRF). What gives? Any suggestions? I have been told its the shift fork wearing down. Can anyone confirm?

Thanks

Andy

[grayracer513]

The shift fork is probably bent, but it's the victim, not the perpetrator. If it isn't bent, it will be.

The problem is that the locking lugs on the sides of the 3rd and 5th pinions are worn and have lost their ability to hold in gear under power. The third pinion is then forced out against the fork, bending and wearing it.

[mtrdrms]

The shift fork is probably bent, but it's the victim, not the perpetrator. If it isn't bent, it will be.

The problem is that the locking lugs on the sides of the 3rd and 5th pinions are worn and have lost their ability to hold in gear under power. The third pinion is then forced out against the fork, bending and wearing it.

Thanks for the reply gray. It sounds like you know what your talking about. So do I have to pull the motor and split the case for this or is it something I can do myself?

Andy

[grayracer513]

So do I have to pull the motor and split the case for this or is it something I can do myself?

Yes, of course, the cases must be split. You don't think you can do that?

[Gunner354]

Just curious. What oil have you used?

[mtrdrms]

Yes, of course, the cases must be split. You don't think you can do that?

No. No I don't.

Just curious. What oil have you used?

Amsoil 10-40

[YZKnine]

Is it just popping out of fifth?

Are u having a hard time finding neutral, also?

If u are, there is a open race that has 10 1millimeter bearings.

Once the race starts loosing these bearings...popping out of gear becomes a real issue.

Solution replace with the 07 Close race bearing and it will shift smoothly & stay in gear.

[mtrdrms]

Is it just popping out of fifth?

Are u having a hard time finding neutral, also?

If u are, there is a open race that has 10 1millimeter bearings.

Once the race starts loosing these bearings...popping out of gear becomes a real issue.

Solution replace with the 07 Close race bearing and it will shift smoothly & stay in gear.

Yes, in fact, it is hard to find neutral. Especially after this started happening. What bearing is it?

[kawazooki_doc]

mine did this and I just went and replaced the transmission forks and detent, so I'm not sure which one fixed it...lol. When I split the cases some of the output shaft gears looked chipped and one of the forks was wearing down so it was probably just the smart thing to do and change them all. Cost to do it myself was only about 300-400. Its really not that hard either. I have never split the cases before in my life and I got it done in about 3 days. Of course I had to make a run to the tool store a couple times to get things, but it was well worth the experience.

[grayracer513]

Is it just popping out of fifth?

Are u having a hard time finding neutral, also?

If u are, there is a open race that has 10 1millimeter bearings.

Once the race starts loosing these bearings...popping out of gear becomes a real issue.

Solution replace with the 07 Close race bearing and it will shift smoothly & stay in gear.

The bearing in question is located on the roller end of the shift cam indexing arm ("stopper lever" in the parts book). It has 7 balls, not 10, but has bee a problem. It was used on the '06 only:

https://www.thumpertalk.com/forum/showthread.php?p=4922391#post4922391

However, being hard to find neutral is usually the fault of a clutch that doesn't release well, and is somewhat common on the YZ450. You can check for the roller issue, but I believe you will find you have the worn lug problem with 3 and 5 on the mainshaft, as I said earlier. If the roller were broken, your problem would be with most of the gears between 1st and 5th, and not so much those two.

[YZKnine]

Yes, in fact, it is hard to find neutral. Especially after this started happening. What bearing is it?

Gray gave U the link, where I got my info from.

In the Diagram #6 (Stop lever Assembly) was what I replace and Bingo , good as new!

[YZKnine]

The bearing in question is located on the roller end of the shift cam indexing arm ("stopper lever" in the parts book). It has 7 balls, not 10, but has bee a problem. It was used on the '06 only:

https://www.thumpertalk.com/forum/showthread.php?p=4922391#post4922391

However, being hard to find neutral is usually the fault of a clutch that doesn't release well, and is somewhat common on the YZ450. You can check for the roller issue, but I believe you will find you have the worn lug problem with 3 and 5 on the mainshaft, as I said earlier. If the roller were broken, your problem would be with most of the gears between 1st and 5th, and not so much those two.

10 ?

[grayracer513]

10?

Yeah, ten. Isn't that what I said? ?

[mtrdrms]

Well the link didn't bring me to a diagram but no matter. I see that I will have to do this work myself. I got a couple of quotes ($2k - $3k) for the work and thats out of the question so here I go. The motor comes out today. Will I need any special tools besides a puller? I have a service manual but if someone could post a link to exactly the suspect part that would be great.

Thanks

Andy

[grayracer513]

Well the link didn't bring me to a diagram but no matter.

Maybe didn't read through the thread far enough:

https://www.thumpertalk.com/forum/showthread.php?p=5115833#post5115833

A flywheel puller should be all you need if you have to open the trans. Check the index lever before you pull the engine, though. I don't think that's the problem, but if it is, it's much easier to fix.

[YZKnine]

Yeah, ten. Isn't that what I said??

?