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Posted by badboy194
- April 18, 2015, 12:41:26 PMYour fluid should be clear. The heat turns it from clear to yellow to brown and causes it to crystalize. If your fluid is brown, there is probably going to be some sludge on the bottom of the reservior. I have heard stories of many people having to replace their clutches at 5000-7000 miles. I would suspect this was their problem. Hopefully this is your problem because it is a very cheap fix. Either way, now you will have clean fluid so there is no loss. Make sure you cover your bike before opening the reservior.
Posted by shunter v8
- April 17, 2015, 11:54:13 AMThat is interesting and symptoms are similar,it's why only in second gear is confusing me. I have not changed clutch fluid so would do no harm to do it. Thanks
Posted by badboy194
- April 17, 2015, 01:29:18 AMIt is a shot. How old is your clutch fluid? I had something similar to where the little hole in the bottom of the reservoir was clogging up with old fluid that had crystallized. At certain rpm ranges it caused the clutch to disengage. I'm not sure if that matches your description of a surge.
Posted by shunter v8
- April 16, 2015, 04:15:00 AMThanks guys, it is a 2004 model,it has done 30k miles, it has not got the heel/toe gearchange lever it has a chrome one on it. This fault is happening well before a rev limiter would kick in. i will check ecu connections and report back, it does feel more elecrical/ fuel related but i am open to try anything.
Posted by Bucko
- April 15, 2015, 22:59:12 PMI'm not sure about other model years but my 01 definitely has a rev limiter. I hit the limit occasionally when downshifting to pass.
Posted by Troll
- April 15, 2015, 18:13:23 PMI've been thinking about this, and 1, I don't believe there is a rev limiter on this engine. The redline is 5,900....but this is not about that, since it would be much easier to hit the limit in 1st...Now..some seemingly unrelated questions...How well and accurately does it shift? Is there any funny noise related to this problem? Do you still have the heel portion of your shifter installed? What I'm getting at is there has been some indication that the early models had an issue with 1-2 shift forks. I know mine had a few teeth knocked off the cluster gear, and a bent 1-2 fork when I bought it. It would hop out of 2nd and slam back in under a load....Just a thought....Like the old joke: "Doctor, it hurts when I do this"...Doctor: "Stop doing that!"
Posted by Bucko
- April 15, 2015, 17:30:09 PMI think the rev limiter kicks in at about 5k but not certain of the exact number.
The ECU is located under the seat beside the battery. Easiest to remove the battery first to get at the ECU.
I've had an ongoing issue with the female connector pins breaking - easily spotted by looking closely at the 'mouth' of the female pins.
Posted by shunter v8
- April 15, 2015, 06:10:41 AMThanks guys, i would say it happens at RPM rather than mph, and only in 2nd gear, i tried to get it to do it in first and third but it did not do it. where abouts is the ecu located and i will have a look at the connections. It has not reved out enough for it to be the rev limiter as it happens fairly quick after hitting 2nd gear.
Posted by Bucko
- April 14, 2015, 23:08:30 PMSounds similar to what I feel when I hit the rev limiter - is it possible you're hitting the rev limiter only in second gear? It wouldn't be weird that you cant go fast enough to hit the rev limit in 4th and 5th, but I would think you should be able to hit it in 3rd (and for sure in 1st & 2nd 
Or, could be your ECU is not measuring RPMs properly. Check the ECU connector pins - That's been a trouble spot for me.
Posted by holycow
- April 14, 2015, 22:32:41 PMLook closely- does it always happen at the exact same speed (not rpm but mph)? Hmmm... or something slipping inside the throttle body...?
Posted by greenbarn
- April 14, 2015, 17:10:43 PMThat is weird.... So just skip second gear... 
Posted by Troll
- April 14, 2015, 17:07:08 PMI gotta think about this...weird
Posted by shunter v8
- April 14, 2015, 15:59:38 PMYes only second gear. That's what I find so strange about it.
Posted by Troll
- April 14, 2015, 15:44:16 PMThis is ONLY in 2nd gear? Very strange...
Posted by shunter v8
- April 14, 2015, 14:07:52 PMOkay latest update,I had two of these light up spark plug caps so I changed them for two NGK ones I had in the garage and took it a spin. Unfortunately it's exactly the same I will try and explain the symptoms better. I got the bike warmed up and did a standing start,first gear under hard acceleration no problem,second gear starts pulling then it's like hitting a very bad flat spot then getting full power back and then it does the same again almost straight away we are still in second gear,third,fourth and fifth gear all fine under hard acceleration. It has vance and Hines on it which I thought may have been the culprit,I had to get the bike government tested when I bought it and I had to put an original exhaust on it then and it was still the same.