When this happens with a car tranny, it's time to rebuild. Can't say for sure if that is the case with bikes, but I'd bet on it.

 

bikes dont have synchos, and it sounds like youre gonna need a rebulild

 

That makes absolutely zero sense whatsoever [&:] 520 conversion has nothing at all to do with how much torque the bike puts out. It's just a thinner chain to save a pound or two... that's all. The motor is still going to put out the exact same peak torque through the clutch regardless of what you do with the chain or sprockets. Now if you changed the gearing, say down in the front or up in the rear, it would take less torque to accelerate at the same rate as you would stock, thus putting LESS strain and torque on the clutch and could mask a slipping clutch. But regardless the peak amount of torque the engine can physically transmit through the clutch will be exactly the same regardless of chain or gearing. When I changed my gearing the reason I decided to go up in the rear instead of down in the front was to put less strain and torque through the chain itself


Back to the original problem.... I'm having a similar issue... every once in awile jumping from 3rd back to 2nd, especially if it's a soft easy shift. I believe it to be the shift star and/or possible broken detent spring. I'm gonna go ahead and replace it with an EVO shift star kit from Factory Pro. I've read alot of reviews on this thing and everybody raves about it. I'll try it and see what happens!

http://www.factorypro.com/products/s...ctory_Pro.html

 

anyone notice that this thread is from may? plus by his sig i would say he got rid of the bike and bought a 1000 rr.