Originally Posted by
oyster
AJ is right. This is 3rd gear seizing onto the shaft. In the worst case it locks solid and of course pulling the clutch in doesn't save your butt. As Craig Shirriffs, he told me it was the nastiest highside he's ever had, all on a humble little RG 150. The fix is to use a top quality LOW viscosity gear oil about 100ml overfilled. So this, makes for 1100ml wet change, 1150 dry change. In the eraly days we had this strange noise in a few bike only on certain corners at Ruapuna. Using good oil and the extra 100ml has seen NO PROBLEM ever since, (we're talking 40 bikes over 2 years here!)
But keep an eye on foaming and catch bottle problems tho, we've had two with persistent foaming and overflow probs, acually a rider problem in the end.
To fix your bike replace the clutch shaft complete with gears (it's a "sealed" assembly)
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