[KingNothing50]

Ive got about 5300 miles on my 9... Great machine... I just fixed my loose clutch nut a few weeks ago... Now 2nd gear is going bad. I have read some stuff on here, but im not real sure what to do. What will cure this problem???.... 2nd gear is okay if you baby it through it... otherwise it pops in and out rapidly......

Whats the best way to fix this?

How can I keep if from happening again?


Thanks.

 

[Irish4life]

Your shift fork is bent, sorry.

You need new shift forks and to under cut your tranny gears.

 

[Hink]

Replace the shift fork, and back cut gears. This is only done by a complete tear down. Average cost if someone else does it, $1200 and up... If you do it, about half that. No other way to fix it. Sorry bro.

 

[KingNothing50]

back cut gears?... any one have any recommendations?

 

[Zoom]

Here's a couple really good thread on what back cutting or undercutting the gears does and what it looks like. There's also a couple places mentioned that do the work, and both have been used by a few members on here.

http://www.m109riders.com/forums/showthread.php?t=108935

http://www.m109riders.com/forums/showthread.php?t=107990

 

[KingNothing50]

I have swapped out ATV transmissions before. So im sure ill tackle this project myself. I haven't read into it to far.... but can you remove the bottom half of the engine case without pulling off the cylinders??

 

[Foo]

I have swapped out ATV transmissions before. So im sure ill tackle this project myself. I haven't read into it to far.... but can you remove the bottom half of the engine case without pulling off the cylinders??

No...I believe it'll be a complete teardown.

 

[Zoom]

No...I believe it'll be a complete teardown.

:agree: It's a complete teardown. If you notice in the threads above, they basically rebuilt the motor when doing it.

 

[KingNothing50]

:agree: It's a complete teardown. If you notice in the threads above, they basically rebuilt the motor when doing it.

Can anyone else confirm this? Or tell me why you can't just pull the bottom case off? Thanks

 

[Zoom]

Contact JUtah, he can explain it since he's done a couple of them. I think it would be hard to hold all the parts in place if just removing the bottom end, since the crank and all is contained in it.

http://www.m109riders.com/forums/member.php?u=19592