Nuts in a blender.....

[KDH123]

As the subject line reads, that's what the gear box sounds like when I put it in third. All the other gears seem fine.  Drained the oil, looks like my daughter poured glitter in it.  Anyhow, my rappy has seen quite a few desert races, alot of practice and this is the first real problem I have had with it, so I can't really complain. I service and change the oil religiously after every 3 rides and clean the air filter after every ride. Probably why it has lasted so long. 

It is time for a teardown though. I am missing a race this weekend because of it and I want to get it up and running as soon as possible.  I am looking for some info in case I am missing anything that I should be doing when I take this thing down.  I am going to replace what needs replacing in the transmission including new bearings. I am also going to drop in a +5 hotrods crank, new bearings, a JE 11.1 piston. I am ordering new bolts for the head and cylinder, new cam chain and an EBC clutch. I am not going to do anything with the head at this time, don't really have the money for it right now, but I want to get the bottom end in order since I am going to be in there.  Are there any other parts that I may need to consider while the cases are split? Are there any maps for the pciii that will be close for this build?  I will be running a hc2, stock valves, stock throttle body, dynatek programmable, prodesign intake with k&n, protech lid.

[Tim Barker]

I have heard of a few having issues with 3rd gear they are making billet replacements for them now give Keith Mulky a call at 918-638-0369 he does have them available.
I am pretty sure White Knuckle also has them.

[preddy08]

I have heard of a few having issues with 3rd gear they are making billet replacements for them now give Keith Mulky a call at 918-638-0369 he does have them available.
I am pretty sure White Knuckle also has them.

Tim, is there a HP level where this becomes necessary?

I've noticed mine has a hard time shifting into third, but only when its been drag raced repeatedly.

[KDH123]

I take it the billet gear is going to be more durable? I will give him a call for pricing info, etc.

On a side note, the pivot swingarm bolt that holds the rear of the motor is a muther to get out! I only got it to move about 3/4 of an inch.  Am I missing something here? I was thinking I may just have a really bad wear spot that is hanging up, but wont know until I get the thing all the way out.

[Tim Barker]

I have heard of a few having issues with 3rd gear they are making billet replacements for them now give Keith Mulky a call at 918-638-0369 he does have them available.
I am pretty sure White Knuckle also has them.

Tim, is there a HP level where this becomes necessary?

I've noticed mine has a hard time shifting into third, but only when its been drag raced repeatedly.

I don't think it is hp related just something that is starting to show up, some break and most don't.

[KDH123]

A couple of fellow racers of mine seem to think I did it when I threw a digger in my last race. When the bike rolled and the sudden stop of the wheels when it hit, might have chipped or broke a tooth.  Don't know for sure, but I know that once I was upright again and racing, the tranny got stuck in one gear and would not shift for about 2-3 miles, then all of a sudden started working again.