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During my race on Saturday about 15 miles in I lost 5th gear, it feels like I can click up into it but it just acts like a slipping clutch when I get on the gas, sometimes it'll catch briefly then free rev again.

I stopped briefly to have a look at the shifter and stuff while on the course everything looked good my oil drain bolt was still in place, however upon pulling into camp after the last 135 miles I noticed oil spewed all over my bike, oil drain bolt was missing for who knows how long.

I'm gonna get into the bottom end sometime this week, I'm suspecting to find something simple as a bent shift fork but I'm not sure. (maybe some additional damage due to no oil)

Anything else I should take note on? I have my Honda service manual ready to go.

I will be posting pics of ASAP.

Where the 2 gears engage are rounded off and is forcing the gears apart.

Your shift fork is TOASTED! you may need new gears or machining done on them and possibly a new shift fork shaft.

This was needed before you lost any oil, now this is different story, who knows what may be needed.

It's leagal to do a tranny as long as your mates dont find out.

Your masterlink clip isnt gold, thats your problem right there....

AlisoBob wrote:Your masterlink clip isnt gold, thats your problem right there....

Totally! How ghetto...

135 miles with no oil......Time to hope for the best..

bummer dude... count on 2 gears and the C fork and thats not counting the damage from running it dry. good luck, mang

sorry to hear and bad luck. hope the damage aint too bad. plz post up pics so we can see the damage. good luck with the rebuild.
ps, use genuine oem bearings. not taiwanese ones.

I think I found the problem...

http://xylicon.com/box/otherstuff/trans_problem.jpg

http://xylicon.com/box/otherstuff/trans_problem1.jpg

Other than that, everything else seems to be in pretty good shape.

http://xylicon.com/box/otherstuff/tranny_small.jpg

More pics to follow.

holy shit!, thats the worst wear ive ever seen. that doesnt look like it was caused by oil starvation though. appart from that worn gear everything else looks in order which isnt too bad of an outcome. usually its 2nd and 3rd gears that wear down first in a tranny. why would fith be so hammered for?
there must have been some serious clutchless shifting abuse some where.

Definitely not from me, previous owner. This is the first time I've gotten into the bottom end since I bought it.

that fork has to be hammered, if not, look for some missing shims.

dannygraves wrote:that fork has to be hammered, if not, look for some missing shims.

x2 somethings gotta be not right with it to look like that.
all your other gear dogs look alright, just that 5th one been chewed to shit.

ive seen a few 5th gear cogs like that when the boys used to gear them for the local dessert race they blew 5th the dogs in my 01 were like worn not that bad but enought that it wouldnt hold in gear

What am I looking for on the shift forks? As far as I can see they are fine, they aren't bent, unless I'm missing something.

What do you mean by shims? The thrust washers?

i beleive what he means (danny please correct me if im wrong) is if you put the shift fork on its shaft, the contact surface where it contacts the gear should be straight horizontally when you have your shaft straight vertical. ( 90 degrees angle)

any slanting, bentness, or wear on the selector may suggest it has been bent, therefor not allowing 5th gear to fully engage, hence causing it to slip out of gear often which will leave you with gear dogs like the one you have shown us.


if you are missing a shim(spacer) then that means your selectors may be ok but that your gear shafts are sliding sideways and not allowing 5th to engage properly.you should refer to your manual and check that your gear clusters are complete with no worn down shims/spacers.

were there spacers on either end of both shafts when you took the tranny appart?

other than that, it could be your shifting drum worn out but that is highly unlikely.

The shift fork will / should have severe wear on it and melted smeared alloy around it from the gear rotating against it.

CR500R7 wrote:The shift fork will / should have severe wear on it and melted smeared alloy around it from the gear rotating against it.

Correct you are sir, it has a nice groove in it.

it may not look like it, but it has to be bent. replace it.

I've been going through the trans piece by piece so far I'm looking at two gears, a shift fork, and a bushing replacement.

Upon going through my trans I've noticed that the tooth counts on 4 gears were that of the year 1992. My bike is a 1997, what is the reason someone would swap out 93-01 gears with 88-92 gears? What does it give me, more top end or low end?

Manual does not tell me.

And I'm too stupid to figure it out.

Upon further research with the engine #PE02E-5000661 the motor seems to be a 1991 so maybe the gearing is what it should be.

On the bright side your chain had plenty of lube and looks to be in great working order.

Xylicon wrote:I've been going through the trans piece by piece so far I'm looking at two gears, a shift fork, and a bushing replacement.

Upon going through my trans I've noticed that the tooth counts on 4 gears were that of the year 1992. My bike is a 1997, what is the reason someone would swap out 93-01 gears with 88-92 gears? What does it give me, more top end or low end?

Manual does not tell me.

And I'm too stupid to figure it out.

Upon further research with the engine #PE02E-5000661 the motor seems to be a 1991 so maybe the gearing is what it should be.

Your Tranny has the same 1st, 2nd and 3rd gears, 84-01 all share the same bottom 3 gears.

Your Tranny gears 4th and 5th are geared slightly lower speed than the others, so you will not be as fast in 4th and 5th as the 84-87 and 93-01 Tranny.

Your top speed will not be as fast as the others.

PIctures people pictures...i'm in need of finding out what my 5th gear is and this would help me no end.

Thank you CR500R7, while I have it apart I think I'm going to put 93-01 gears in it. I wouldn't mind some extra top end.

asteroid, I'll post all the pics I've taken thus far later on today.