Gearbox - 3rd gear

Hi Gents

The long running saga of my attempt to love my berg continues...

Cutting a long story short, I bought and shortly after blew up a '99 400 e-start, I then bought a 99 non e-start 600 and fitted it (eventually after much P***ing about)

Wouldn't start, so off it goes to DCR to "fix it but not spend loads on it" (am getting a bit fed up now you see!!! - could have bought an 03/04 with the cash i spent on it by now) .

Credit to them, turned out to be the stator and they sorted it quickly, but also turned out that previous owner (of the 400) had put the 04 top coil on. Luckily I bought the loom with the 600 motor and the coil was there.

One new stator later, I get it home, kick it up (DCR tell me it doesn't smoke, is quiet and generally appears to be a pretty good motor) and go off me merry way and find that third gear is horrible, and there's no 5th and 6th, and I can't get it back in neutral when i stop without switching off and "jiggling" back and forth.

No blame to DCR by the way, the've been really helpful throughout with my bitsa i98/99/00 berg but just a quick question, is it liable to be something simple that doesnt require splitting the cases as that's beyond me I think.

It goes into third then spins as if it hasnt selected or missed a gear or even like there's teeth missing or something so i have to short shift to 4th. Given the torque of the beast is not that much of a problem but if its an expensive fix or the start of another moto-disaster, it needs to go this time...

I read somewhere about selectors etc getting burred but can't find it again. I've still got the 400 engine and I have to say that the 'box on that was IMHO superb up and down - I though thtat the 600 might be a 4 speed FC but if thats the case, would it have had the lighting coils etc (which it did before the stator swap)?

Is the 99 clutch and the selector mechansim the same across all models and if I was going to be brave, does swapping these require anythong more than draining the oil, taking the LHS case off and swapping the bits?

Also, finally should the older 600's vibrate like hell and any suggestions why it feels like its weaving all over the road and pulling to the right - torque reaction?

Any help would be appreciated

Cheers

Frustrated Chris

I ony got the message very quickly before going to work so haven't read the details. I take it this involves splitting the cases etc.

I would not feel confident to do this at all, though I could have a go on the already knackered 400 couldn't I, to practice?

I only ever bought the bike for a bit of green laneing and fun. Seems (i'm going to blaspheme) I would have been better to go japanese, nah, maybe not but god its a labour of love and pot full ofmoney required .....

Disappointed and frustrated and resigned to yet another big bill

Chris

Cheers Taffy

PS you've been incredibly helpful in my 10 months as a berg owner- in fact you put me onto the engine too, I remember and sold me some brake bits too

All the best

Chris