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4th gear troubles
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Posted by: #78honda450r

We have two 04 450R's and lost 4th gear on both of them. Is anyone else having this problem? One was rebuilt by a very reputable company just about 6 weeks ago and it lost it's 4th gear again. When I say lost it will go in but POPS out. Is there a fix for this?? Thanks

Posted by: thrasher_ex

you mean you got the tranny rebuilt? if the tranny was the problem and you got it rebuilt and its the same problem again, go back to the place you had it rebuilt. it also sounds like your clutch could be slipping...

Posted by: ACEOUTDOOR

Sounds like a worn shift fork or broken shift drum to me, not the gear itself.

Posted by: #78honda450r

The center shiftfork and 3rd, 4th and 5th gears was replaced on the one that got rebuilt. It ran fine for about 8 motos or so and about 3 practices. Then today it started popping out of 4th again. Both have new clutches in them.

Posted by: ACEOUTDOOR

Check the shift drum. Alot of them are cast .

Posted by: #78honda450r

Is this a typical problem? Or just our luck? The quads have different riders so I don't think it is the way they are being shifted.

Posted by: XCRACER26

I went a whole season of XC racing and no problem at all.

Posted by: MixMasterMike

sounds like an actual casting problem with your ATV. contact honda. mine had countless hours on it and all I do is change my tranny fluid & oil regularly

Posted by: KRMit

A friend of mine had that problem with his '05. Instead of fixing it though, he traded it in on an '06 so I'm not much help.

Posted by: 370kingR

Just sounds like someones not using the clutch and now has a bent shiftfork and is wearing down the gear dogs. It will only get worse.
2 machines, same problem. User error i think. Im not bashing, im just saying who ever rides these bikes needs to use the clutch.

Posted by: #78honda450r

Not taken as bashing. You are correct, they have not been using the clutch especially on holeshots because honestly we did not realize it was hard on the tranny. We know it now. $$$$$
We will fix these and try to make it until the 07's come out.
Thanks for the imput.