It finally happened.............

[DragonRider]

Well it fianlly happened, second gear has been popping out, well when I left for work this morning went to shift into third gear and it wouldnt go in, downshifted to second, no problem, down to first no problem, went back up through the gears, still will not go into third, had to turn around and get the other scoot out to go to work, glad it didnt happen after I got halfway there.

 

I have been knowing I needed the split washer fix, well now looks like I am forced into it, thank goodness I have the other bike to ride, the bummer is finally got everything working right on the 1st gen, and this happens, guess I will start tearing it down either this weekend or next. I will have to go back and find that excellent tech article about doing "The Fix". At least this is the last thing that needs to be done to make her good again!!!

 

Got to get some help over to pull the engine out, maybe I can get 86er and Wingman to help in that area, maybe between the 3 of us we can geterdone.

[Wizard765]

This sounds like a different problem. I had this happen as well and it is not the 2nd gear issue. There is a star shifter or cog (not sure what it is called) that has a number of pins in it. The outside star washer over time gets weak and the pins come loose. If the pin for 3rd comes out or loose you cannot get it to shift. Easy fix.

Take clutch cover off and look behind and to the right of the clutch. I just pushed the pins back in and bent the tab back over it to get me by for the time being. Squeeze told me that the VMax unit from the 2001 and up is a direct replacement which is cast and this will never happen again. I have since done that and it works better than ever.

I can look up the parts for you if you like.. PM me if you have any questions..

 

Wayne

[Yammer Dan]

This sounds like a different problem. I had this happen as well and it is not the 2nd gear issue. There is a star shifter or cog (not sure what it is called) that has a number of pins in it. The outside star washer over time gets weak and the pins come loose. If the pin for 3rd comes out or loose you cannot get it to shift. Easy fix.

Take clutch cover off and look behind and to the right of the clutch. I just pushed the pins back in and bent the tab back over it to get me by for the time being. Squeeze told me that the VMax unit from the 2001 and up is a direct replacement which is cast and this will never happen again. I have since done that and it works better than ever.

I can look up the parts for you if you like.. PM me if you have any questions..

 

Wayne

 

 

 

:sign yeah that::sign yeah that::sign yeah that::sign yeah that:

 

When 2nd starts to go you can still shift.

[Squeeze]

Wayne's right, It's the Star Washer Pin behind the Clutch Basket.

 

There's a Ratchet Mechanism which is operated by the Shift Shaft, if the Pin isn't in Place anymore, the Hook on the Ratchet isn't biting anymore. Though, no upshifts possible. Pretty easy fix.

[BEER30]

Sounds familiar as well . Son's Blaster (Yamaha ATV) did the same darn thing. Don't know how hard to do on a 1st Gen, but only took me about a hour to replace the star pin on the Blaster.

 

 

BEER30

[Grandpagak]

This sounds like a different problem. I had this happen as well and it is not the 2nd gear issue. There is a star shifter or cog (not sure what it is called) that has a number of pins in it. The outside star washer over time gets weak and the pins come loose. If the pin for 3rd comes out or loose you cannot get it to shift. Easy fix.

Take clutch cover off and look behind and to the right of the clutch. I just pushed the pins back in and bent the tab back over it to get me by for the time being. Squeeze told me that the VMax unit from the 2001 and up is a direct replacement which is cast and this will never happen again. I have since done that and it works better than ever.

I can look up the parts for you if you like.. PM me if you have any questions..

 

Wayne

 

 

 

i had the same problem with mine 83.. im convinced that is your problem also.. a lot easier fix..