Tranny issue

[SandGeek]

I lost second gear yesterday out on the sand. Still hits in 1st and 3rd, no second. Heard a loud grind when she let loose. Lotta shards laying in the bottom of the case.

My bikes a '99 so 9 year, half a dozen owners (who knows what those monkeys did for maintenance)...I figure its just one of those things....but I am curious to know if there are any 'known' transmission issue with the EX?

I will post pics when I get the case apart but first I have to wrestle the fricken frozen swingarm bolt. Spent an hour already today beating on in...:grr:

sg

[duffman1483]

I actually had the same question last year before my rebuild. I have a 2001 and Sparks was p&p'ing the head and boring the cylinder and all, I took the bottom apart to put my HD crank in. While in there I took apart the gears to make sure they were all within spec and replace the shifter forks just for peace of mind. I have to admit, I have had this bike for some years now, and really the heaviest wear was on first gear and third gear, but the wear was negligible as they were still well in spec range, and really showed no signs of wear. Totally shocking, and when I talked to Sparks about it, they told me that they have one of the strongest bottom ends they have seen and have had no trouble from them other than shift forks.

[SandGeek]

Here is what is left of second gear....the rest is spread throughout the rest of the tranny

http://i98.photobucket.com/albums/l272/SandGeek/gears002.jpg

http://i98.photobucket.com/albums/l272/SandGeek/gears.jpg


The new tranny is sittin on the bench. Gotta get some bearings and put it back together.

[duffman1483]

I gotta say I have blown tranny's before, but that takes the cake, sorry dude!

[duffman1483]

while you're waiting on bearings, don't forget to replace the stock snap rings. I have heard they have a tendency to fail.

[brokenmike]

I broke a tooth off of 2nd gear and had to end up replacing 3 other individual gears. Be sure you replace the mating gear to the gear that broke. It shouldnt look too good

[SandGeek]

Originally posted by brokenmike
I broke a tooth off of 2nd gear and had to end up replacing 3 other individual gears. Be sure you replace the mating gear to the gear that broke. It shouldnt look too good

I grabbed a whole new transmition. I don't like splitting the case that often :p

[duffman1483]

A new transmission? How much did that run you?

[Bill Fuller]

This is or was a very common problem for the 400ex. I went through 2 transmissions myself both times second gear. I owned a 99 and a 01 both machines did the same thing.

[hondaman146]

i own i 2000 and my second just went out a few weeks ago but i think its a shift fork but i can't afford to fix it so i just skip second and go to 3rd

[SandGeek]

Sorry, by 'New Transmission', I meant a complete other Transmission out or an '04. Shifting forks, shift drum...right down to the little washers that protect the case. It was about $150 to my door.

[Bill Fuller]

Originally posted by hondaman146
i own i 2000 and my second just went out a few weeks ago but i think its a shift fork but i can't afford to fix it so i just skip second and go to 3rd Are you serious???:confused: There are pieces in there and they are going to cause ALOT of problems if not taken care of.