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Sounds like a bent shift fork. While accelerating you can feel the power cutting in and out quickly. The problem will get worse if you keep pushing 2nd gear till it slips. You can learn where (at what RPM) it wants to jump out and start shifting before it jumps out. The long term fix is opening the transmission and fixing the bent shift fork.
I fear that whatever bent the arm forced the shifter with a lot of pressure and now, in addition to the bent arm, the bike has a bent shift fork. It is the bent fork that causes the shifting problem. The shift fork is a part of the transmission and is costly to fix. Below is a diagram showing how the shift drum rotates to move the forks left and right to change gears. Check with a Kawasaki shop to confirm my diagnosis. Please rate my answer.
If the clutch is working as it should, the shifting problem is unrelated to the clutch. The bike has a bent shift fork or two. It is costly to fix. Below is a diagram of how the shift drum moves slider gears to change gears. If a shift fork is bent, it doesn't move left and right freely. Please rate my answer. Thanks.
There could be several reasons for the shifting to not be working properly. The most common is that there is too much slack in the cable and you need to re-tension the cable. There could also be something broken in the shifting system or bent.
Best thing to do since index shifting requires precise fixing to make work properly is too take into your local bike shop, they can diagnose the issue very quickly and let you know what is the remedy.
You should be admired for being able to tear into the guts of this bike, find a problem and fix it. Most guys would back away, and rightfully so if lacking mechanical ability and tools. Strange that only 3rd gear is affected. The only possible thing I can think of is to stick in new fiber clutch plates. The plates have been used for 22 years and thousands of miles. Time to replace them just on the principle of the matter. Post a comment on how things turn out!
This doesn't sound like a clutch related problem. A bent shift fork in the gearbox could be present. But the fix for the problem may be a minor adjustment away. Try lowering the front of the shift lever one notch on the shift shaft. It my be that the lift you normally give the shifter is just not quite enough to fully engage 2nd gear.
Well. I'm a motorcycle mechanic and my 2004 RMZ 250 recently did the same thing, The Shift forks inside my transmission actually bent and were not moving the gears as far as they needed to go and eventually got to where it quit shifting all together, recently also repaired a CR 125 That wouldn't shift at all and it was the shaft the shift forks go on was bent and hung the shift forks. Sounds like your shift forks are bent to me though.
Could be a broken tooth on a gear that just hasnt broke yet, or a shift fork may be bent jammin things up. Number of things coulda caused it, but your gonna need to split the cases to fix it either way. Good Luck to ya.
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