A year and a half ago I had to remove my Primary chain case and open my tranny so that I could replace both the drive gear and sprocket. Everything went well replaced the bearings and seals and put it all back together. It's been running like a champ ever since. Not that hard to do either the manual is great. But one thing I have been having an occasional issue with is that Neutral can be a big PITA to find some times and there have also been times that when shifting from one gear to another I will occasionally wind up between gears like I am in neutral but I'm not. I have to hit it again to get the gear usually I have to hit it down not up to catch it other wise it bogs down as it goes up to the next gear. So after doing a little research I am finding that I may need to do some shim work on the shifting forks to get things tight again, it does feel a little sloppy. HDF Tech can you provide some instructions for this? Things that have been learned from experience that the manual doesn't always have.

 

Check all the shifter linkage to be sure it is not binding and secure.

Make sure the lever at the transmission is secure.

Check clutch adjustment.

Check shifter pawl adjustment.

No shims on the shifter forks, there is a thrust washer on the shift drum, but I doubt that has anything to do with your problem.

Most likely just an adjustment issue.

 

+1 on dan's info

 

As previously stated. You may need to adjust the shifter pawl to ensure that it is centered. Also If your clutch is out of adjustment or your shift linkage is loose at all it can cause your problems. Check your primary chain to ensure that it too is adjusted properly.