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Sorry to hear. Rounded off dogs and windows may be the cause and this puts the shift fork under great tension. Something else may be the cause but these are mostly extensive repairs.

The gears mostly pop out on certain revelations of the engine. Like you mentioned, on throttle. Adapt to a different style of riding or skip second gear when riding fast before fork is bent.

I report a complete healing of hard shifting and strange occurrences on slopes with thicker oil. Oil is always being mentioned to provide a possible cure. Also check the oil level. The oil I started off with was the cheapest but fresh and like specified, It worked great on my former bike and other users of the product had no complaints. Because of the price there were extensive reviews, I am certain there was nothing wrong with it. What I turned to was Motul Motorbike Oil, Motul 5100 4t 15W50 4 liter cans.

I wonder if clutching the gears would help. After pulling the clutch and a short throttle one shifts into gear the moment the revs go noticeably down. That would be easier when the engine goes round rough then on smooth running engines.

Check the clutch because some problems with sudden change to higher revs at slow speed are to be expected when the clutch wears out and when there is little free play. High speed together with torque is not always where one encounters clutch problems. Also when cleaning the master cylinder and it was dirty, like brownish and crystallized fluid, the small return hole, somewhere in the system on the bottom, must absolutely be checked and cleaned. Air in the lines can be removed with tying the lever to the handlebar overnight (rope can damage or put dark marks on grips). I had the brake done and with all the experience and tools in the shop they could not prevent air from entering. Use no friction enhancers in the engine oil.

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Posted by aralph

- September 18, 2015, 15:34:35 PM

Quote from: Troll on September 18, 2015, 09:18:25 AM
..This is a HUGE job!..

I had a feeling it would be. Thanks for responding.

aralph

Posted by Troll

- September 18, 2015, 09:18:25 AM

The sooner you get it fixed, the better. When I bought my 1500, that was one of the things that was wrong with it. The PO tried to ride it for a while after bending the fork and did extensive damage. To rebuild the trans, requires engine removal and complete disassembly of the engine. Nice time to inspect the internals...The dealer I had do the job charged me 15 hours labor, and gave me 25% off on the parts..This is a HUGE job! On the bright side, the engine was fine inside, and because I ride like a (more or less) adult, it's been 62,000 miles since it was done with no issues at all

Posted by aralph

- September 17, 2015, 20:08:20 PM

Having problems in 2nd gear only.
Under medium to hard throttle, transmission pops out of 2nd gear into neutral.
It's very consistent. Only under light acceleration will it not pop out.
My mechanic has suggested a bent shifter fork.
Troll, I read in a previous thread you had to change one. How much work does this involve?
Also any other possible reasons for this issue?

thanks
aralph

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