second gear pop out
 

its on a 2006 f4i clutch went out installed new clutch, now when i get to higher rpms it pops out of gear any idea? thanks

Worn shift dogs maybe? My '01 was popping out of 2nd and 3rd occasionally and at high rpm's it wouldn't shift into 3rd at all. I pulled the motor and 2nd gear was kinda scorched and the dogs for 2nd and 3rd were pretty worn. I haven't put it back together yet unfortunately so I can't say for sure if this is my problem but I don't know what else it could be. I've heard on an '06 you don't have to pull the motor to get the transmission out so it might be a little easier for you to check it out but I'm not positive about that someone else would have to confirm that for me.

alright thanks i am going to do some research and take it apart, I have never had this issue

mine was popping out of third every once in a while, so i went ahead and pulled the oil pan, pulled the clutch and pulled the shift forks. turns out my forks were way out of spec, and my gearshifter shaft was bent from a chain break at 80mph. I replaced the bent/bad/worn parts, and I am hoping it will fix everything. My third gear dog was worn some but it didnt look bad. We will see, when I get the bike all back together next week!

Will still have to split cases to get to the gears...on all 99-06 F4/F4i crank cases. Typically it's the shift fork, 2nd gear dogs, and the slots on 6th gear get rounded off enough so that the vibration under load combined with the play in the shift fork being worn, plus the rounded dogs/slots...she pops out. It gets increasingly worse to where 2nd gear is nearly useless. Mine started at about 10k, then was down to 8k, then before I knew it it wouldn't hold above 5k rpm.

It's a very simple and cheap fix but takes a little time and a bench. If you have patience, moderate mechanical aptitude, and a service manual you can do it no problem. Drop motor, pull cams and head, remove side covers, clutch+basket, oil pan, oil/water pump assy...all top and bottom crankcase bolts. The only special tool I used was a $25 motion pro clutch basket holder to get the nut off. Other than that a typical socket set would work and a pair of snap ring pliers to remove the gears on the main and output shafts. May even go the extra mile and have your cases cleaned at the machine shop.

Here's a few pics from when I did mine...
CBR engine rebuild