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Discussion Starter · #1 ·
I have a 2000 400EX that runs great but will not go into third gear. Its been like this since I bought it a few months ago. All other gears work fine, chain and sprockets are in good shape and adjusted per the manual. I've tried some clutch adjustment but it makes no difference.

When I shift from second to third I let off the throttle, pull the clutch in, lift my foot on the shifter and hold, and let the clutch out. As soon as I let the clutch lever out, even if I do it slow, the shift lever pops down on my foot and it sounds like it goes into neutral then back into second gear.

I've done some research and it seems like either the fork is bent or the third gear dogs on the gear are worn/ damaged. I was going to pull the side cover and inspect the clutch and the star behind the clutch for damage. I've read that these can cause the problem too but I'm doubtful. If I remove the side cover will I need to replace the gasket? Use honda only gasket?

If I pull the engine and split the case, what will I need minimum to change regardless of what I find wrong with the transmission?

Thanks
 

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Thanks for the reply, I have a few of your post saved explaining how the trans works with every gear and the part numbers for each. Looks like a complete honda gasket set is about $50 + what ever I find bad in the trans.

I read somewhere about having the dogs machined if they are just rounded off. Is that possible?
 

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Yes, a good machinist can renew the surface of the dogs if they are rounded from improper shifting and poor engagement - typically the dogs only engage about 30% of their total depth - renewing the engagement surface will weaken the gear slightly and increase backlash, but it will salvage the part and extend the serviceable life of the vehicle.
 
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