'04 FSE 450 gearbox issues!!!
 

Gears have stopped engaging properly......going up the box she is OK if using the clutch however, when giving it "the beans" and clutch-less changes, it goes into every gear but the second you back-off and unload the transmission, she slips into a false neutral (between all gears!!). Going down the box is a similar story...clutch and blip it down and she's OK but if you try clutch-less down changes she's also finding false neutrals. Any ideas??? Just to add......this problem appeared out of the blue (ie no a gradual deterioration in gear changes) and is affect all gears so can only assume this rules out selector forks!! All help welcome. Cheers. Mike.

When did you last change the fluids? Did you notice any excessive contamination in the oil?

Thanks for your reply. Oil changed pretty frequently......no contamination. Got the feeling that what is wrong is mechanical like selector drum movement!!!

If its similar to the two stroke box, there is a spring loaded arm with a roller that keeps the drum in position. Remove the rhs cover and you'll find it there. I think it will be pretty obvious if something there is out of shape.

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I agree!

Haven't been in one of the GG 4T's but they're all pretty similar.

I'd be checking out RHS engine as above. If that checks out, it'll be digging deeper. Given that it sounds like you tend to power shift without clutch up and down you could potentially be looking at shift forks, or even have some dog wear. As it's happening across all gears probably more likely forks than dogs. Either way you'll have to start digging to get to the source of it all.

Cheers for the replies. I dont think there will be any similarites with the 2T engine/box as the FSE450 is essentially a DRZ400 motor. I hear what you are saying about forks and not using the clutch but it's all gears that are affected and the issue appeared in an instant so I cant see all the forks getting bent at exactly the same time.

Copy that. As above. Start with the shift shaft and selector mechanism.

It could be that one of the shift fork shafts is bent out of true, not allowing the shift forks to move freely.

Thanks again for the replies guys.......stuck offshore at the moment but I'll tear it down when I get ashore in 3 weeks time and feed back. Cheers. Mike.

Anders....... you were right on the money......broken spring on the arm. Fiddly little bugger to replace but job done. Cant thank you, Jakobi and Jacob enough for your time and advise.
Cheers. Mike.