Trans pops out of second gear, fix or replace?

[FieroAddiction]

'91 Kat 600, 30k miles. It will go into second, but immediately pops out under any throttle. It will stay in gear if I hold up on the shifter. All other gears seem to work ok. I'm trying to figure out if I should fix the trans or just replace the whole engine/trans with another one. I'm a professional mechanic so labor is not an issue, but I need an estimate of which parts will be needed so I can price them.

A bad Ebay deal got me into this mess. I just finished fixing the engine, if I'd known the trans was bad too, I would have swapped out the whole thing.

[The CyberPoet]

Figure a high estimate of $200 - $300 in parts. 16 to 45 hours in labor.

Cheers,
=-= The CyberPoet

[gsxxx]

Sounds like a bad shift fork. had the same problem with another bike i had. You could be daring and fix it yourself, but that involves cracking the case and digging in there pretty deep.
I'd say, if you can find another 600/750 motor with lower miles, for a few hundred bucks, do the swap yourself, and save yourself some money. then you don't have to get too dirty

[FieroAddiction]

I decided to go ahead and tear it down tonight and see what it needs. What a job it is to split the case!! There are little bolts hidden everywhere. The #3 shift fork is bad as well as the 2nd and 6th driven gears. Looks like about $200 including some new seals. I also found one of the clutch plates broken and the hub worn out. Since I've already got some money tied up in the top end of the engine, I think I'll fix it.