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taking my transmission apart of my 2013 kx450... bike has about 40 hours on it. started grinding and jumping out of gear when shifting from 4th to 5th under load. after splitting cases and inspecting gears, i was surprised to see they all looked like they were in nearly new condition. the only wear i can find on any of the components is on the 5th gear gear dogs. they arent a perfect 90 degree angle anymore, but i wouldnt say they are anywhere near "excessive" wear. i guess my question is.. how much wear is too much? i know these are incredible precise parts, but it's just hard to imagine this is what was causing the jumping out of gear. but on the same note, there is NOTHING else wrong that i can find so it almost has to be this?? ive provided some pictures hoping someone with more knowledge and experience with these transmissions could set me straight. sorry if this posting is in the wrong place, but this is the first time ive ever joined a forum to ask a question. Anyway, thanks to anyone who can help.

James

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Those definitely aren't the problem.  I've seen much worse work just fine.

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Had this happen myself few times different bikes but trannys are about the same every brand. Ive done much worse.  And yours would've gotten worse and will if you re use them.  Replace those two gears and left fork looks like. its not bad but has mark on it so....The one with wear spot .and will be fine I bet:thumbsup:

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That fork looks like the problem to me (last problem).   The gears are not as bad as lots of others I have taken out of transmissions that worked fine.  

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