I also have the same problem. According to a dealer I contacted you would need to strip the whole engine (which is costly) or find a replacement engine. To mee this sounded a bit drastic, so I wonder if anyone can confirm this scenario or if there is a simpler solutionI also have the same problem. According to a dealer I contacted you would need to strip the whole engine (which is costly) or find a replacement engine. To mee this sounded a bit drastic, so I wonder if anyone can confirm this scenario or if there is a simpler solution
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A broken gear will make a clicking noise each revolution of the gear. It will not cause the bike to slip out of gear. The problem sounds like a mildly bent shift fork.
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If your clutch master cylinder is good in all other gears: you can disengage and, shift the other gears with the engine not running and, you have the correct amount of clutch fluid in your clutch master cylinder: to release the clutch: you have a broken 5th gear syncro and, a bent fork remove the transmission and, when you remove the shift cover you will see the problem; you must drain the transmission case remove any metal debris; remove the gear set and, replace the syncro...the fork can probably be re-straightened use clean, new case oil when you reassemble the transmission.
The popping noise is gear dogs trying to engage a gear. You did not say that the bike doesn't shift smoothly so I would tend to rule out a bent shift fork. The neutral stopper pin may be worn or the stopper spring or other springs may be broken (see diagram). Another possibility is a broken stationary gear circlip which would let the gear wander a bit on the shaft. most the parts are available at Babbitt's. Go to www.babbittsonline.com/parts/viewbybrand/parts.aspx
I also have the same problem. According to a dealer I contacted you would need to strip the whole engine (which is costly) or find a replacement engine. To mee this sounded a bit drastic, so I wonder if anyone can confirm this scenario or if there is a simpler solution
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