'04 FE 450 Gearbox Dramas

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Joined
Feb 13, 2013
Messages
3
Hi guys, this is my first post tho I've been a big fan of the site for years now....anyway.

I have a 2004 FE 450 from new, and while riding the Malany Trailride last year, my bike "dropped" out of gear(4th at the time) while under full throttle in dirt biking Nirvana. While trying to select a gear with the clutch in, it seemed like it was passing through the gears internally, but as i released the clutch, it had no drive to the counter shaft or front sprocket. I eventually found third and rode out to the camp site without touching the gear selector for fear of losing drive again.

After a good wash at home, I started it, found first so tried a short ride. It rode fine, selected every gear up to 6th and back as if nothing at all was wrong! I then dropped the oil to find CHUNKS AND SHAVINGS in the oil.....

I have pulled the clutch apart and found nothing wrong, so it would seem like the problem is between the cases?!?!?

Can anyone suggest what the problem may be? Apart from 2 new exhaust valves and servicing, it's never been apart.

Thanks for reading, Ryan, Gold Coast, Australia.
 
When you take clutch appart, did you look under the clutch hub?
Maybe gear selector forks are damaged.

I had exlactly the same problem, I could shift only when bike was stopped and then drive in this gear.
It was problem that recoil spring gearshift mechanism was out of place and touching clutch hub.
look some pict here http://www.husaberg.org/gallery/v/Members/kli/Left+cover/
 

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