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Discussion Starter #1
hey all my 97 900rr hopefully after this I will be able to leave all of you alone at least for a day my 2nd gear has done this twice now I will be on the throttle kind of hard and then all of a sudden the neutral light comes on and it does go into neutral what could this be a bad shift fork bad gear. Thnx in advance everybody owned this bike for a month or so now and now it has turned into one thing after another
 

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Sounds like what happens to a bike when it's been wheelied a lot.
That's all I got. Sorry, i don't know the internals of the tranny...
 

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Typically the bike popping out of gear (2nd usually the first to go) indicates that that gear is going bad or worn. It usually does not cost too horribly much to get a single gear replaced, I think the local place here offers a full rebuild on the tranny for about $800.
 

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Discussion Starter #5
Can anyone tell me were to get the parts once I order them i will break out the manual and go at it
 

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Try motosport.com under their OEM section. They offer 20% off OEM retail prices, and it sounds like you would only have to replace 2nd gear anway!
 

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Discussion Starter #7
so should replace just second gear or anything else while I am there can someone give me a breakdown of what parts or gaskets will have to be replaced going that far in
 

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BR is a friggin motor-bike encyclopedia! I would say you can get away with replacing just the one bad gear, I have seen many people do it. I would definitely have a shop take a look at the rest of the gears though, just to be sure they aren't close to going out as well (will end up saving the bike from getting torn down again later). I am sure you have some gaskets to replace if you crack the case, not sure what other high-wear items you might want to tackle while it is apart. Bladeracer would certainly know, I am surprised he hasn't paid a visit to this thread yet....
 

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Measure and inspect the undercut on the drive dogs, if they are worn, why take the chance. I bought a used Transmission that appeared to be in better shape. It has come back to bight me in the ass, and I will be buying all new gears this time around.
 

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Measure and inspect the undercut on the drive dogs, if they are worn, why take the chance. I bought a used Transmission that appeared to be in better shape. It has come back to bight me in the ass, and I will be buying all new gears this time around.
:plus1:Inspect the shift fork also, a bent shift fork will allow it to pop out of gear, which will in turn round off the dogs on the drive gear. Just don't want to see you replace the gear only to have it pop out again. Have you ever missed the 1-2 shift under HARD acceleration? Your answer will not be used to incriminate you.
 

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Discussion Starter #12 (Edited)
to be honest I have owned the bike about a month and it hasn't seen hard accel or even over 7k since I have owned it it has seen maybe 1\2 throttle
 

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Yea. Jondog is right its from being wheelied and shifting. Its very hard on trans.
Good news just splitting the case is that big of a deal. Just need side covergaskets stator clutch pulse Gen.
Depending on how you funds are is factor on if you even wanna check anything else.
but id atleast check main bearing clearance, rods main oil clearance, rod side to side play.
But tear trans down inspect thegears inside and out. Go thru shop manual inspection of trans check out shift drum usually a grove has become busted and dontpush the fork far enough to slide into gear fully.
iv seen a undercut trans being sold few places. For 3-500 dollars. You'd have to search.
maybe good idea to do compression and leak down test before the tear down to see if would be worth freshen up on top end. Just messing with trans, crank rods pistons all stay connected in top half of case, while serviceing the trans. So unless you absolutely wanna you don't have mess with them.
you can spend good amount of cash if you keep coming apart. So comp test and leakdown see if you'll benifit from hone and rings valve seals valve guides etc.
 

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Hope your prepared lol it gets outrageous pretty quick like. :)
I just did mine beginning of the year!
Would been as cheap to just ordering that remand engine from ebay and wouldn't have long stressful nights.

Are you setup tool wise, or have means to cut weld grind to make some tools needed for the tear down? Clutch center holder good torque wrench castle nut removers valve compressor feeler gauges etc etc...
other than those its pretty easy. Besides its hard to keep forking out more more more$$$
Lol keep us updated with the build
 

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Discussion Starter #16
set up tool wise but if u guys think it will be about the same as that rebuilt engine may as well do it need to check that guy out I guess
 

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You need to price check thing just the 4 sets of rings are 180$ then circlips their cheap
valve seals are 6-7 each per side x8 each then valve guides if needed are 16$ I think.
head gaskets around 80$ gasket kit 100$ main bearings 6$ each there's 10 of them same for rods but only 8.
Ontop of your trans parts shift forks shifter drum gears
oil seals, orings, exghaust gaskets, new crush seals for case. And the unknown little things you may run into.
think that's guys name is Charlie from cyclerus or something outta Chicago with nice remans

I didn't have all the $$$ for the reman so I went piece by piece ordering what I needed. But its all done and put in close to 9000 miles so far :)
we won't talk about cost ;) Errr
 

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had the exact same problem last summer, ended up replacing 2nd, 6th, and a shift fork. did all the work myself, was about $4-500 in parts by the time it was all said and done. search this site, there are tons of threads and how to's on it, very helpful. also, get a manual.
 

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just read a few more replies, try ronayers.com, i believe that is where i got my parts. they have some good diagrams also. when i called a shop, they quoted me i think 8 hours just to take everything apart, so it can get more expensive than the value of the bike REALLY quick.
 

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just read a few more replies, try ronayers.com, i believe that is where i got my parts. they have some good diagrams also. when i called a shop, they quoted me i think 8 hours just to take everything apart, so it can get more expensive than the value of the bike REALLY quick.
Yea Ron Ayers has decent prices too but shipping is crazy from them. Be wise to shop around a Lil bit and group your orders.
ain't that the truth get more expensive then what the bike is worth Really fast! Lol
Even just parts cost us kinda crazy. But if you have to add labor too OUCH...
 
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