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Transmission rebuild advice 5th gear

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  • Transmission rebuild advice 5th gear

    The other day while on the freeway my shifter got stuck whole shifting into 5th gear, luckily I was able to coast to the next exit.
    Eventually after trying to shift up and down for a while i was able to get it out of 5th and get to work using the other 4 gears which worked fine.
    I'm guessing the gear dogs are sheared for the 5th gear, i plan on rebuilding the transmission in the next few weeks, and I have some questions for those of you who have done anything similar.
    what if any special tools will be needed?
    what are some things to look for while I'm in there?
    Anything I should replace while the case is split?

    I bought this kit for $130 shipped 90891-10117-00
    From what I can tell it has all the gaskets needed, hopefully.

    I plan on getting a used set of gears online In case the forks or anything are damaged/bent

    What else would you recommend?
    Thanks!

  • #2
    Tell folks what year bike you are talking about.

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    • #3
      2003 xv1600

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      • #4
         

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        • #5
           

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          • #6
             

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            • #7
              This might be too late but: After my bike was about 8 years old, I took it in for something and they told me about the transmission recall. They said” we're going to have the whole thing torn apart to do that, so would you like to put in high compression Pistons and an electronic ignition?” I said ”how much” and “sure”. I think they charged me an extra $350.00. It transforms the bike dramatically. It revs out much higher and is much stronger. I can keep up with anything.

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              • #8
                Originally posted by JHouse View Post
                This might be too late but: After my bike was about 8 years old, I took it in for something and they told me about the transmission recall. They said” we're going to have the whole thing torn apart to do that, so would you like to put in high compression Pistons and an electronic ignition?” I said ”how much” and “sure”. I think they charged me an extra $350.00. It transforms the bike dramatically. It revs out much higher and is much stronger. I can keep up with anything.
                From what I can tell the recall had already been done on my bike, the pistons and ignition sound like a good upgrade for that price, do you know what the brand of the ignition is?

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              • #9
                Thanks Jhouse
                I was just looking into the pistons and they do seem a bit pricey but maybe if I can find them cheap enough it will at least be doable.

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                • #10
                  Thanks Mort!
                  I watched those videos videthe flip phone footage is kinda hard to see haha.
                  I guess I will film the process when i take care of mine in a few weeks to help someone else in the future.

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