here is a complete list of what should be changed
4XV-18531-00-00 BAR, SHIFT FORK GUIDE 1* 1 $8.09 $8.09
5EB-17221-00-00 GEAR, 2ND WHEEL (37T) 1 $32.58 $32.58
5EB-17261-00-00 GEAR, 6TH WHEEL (26T) 1 $42.97 $42.97
5EB-18511-00-00 FORK, SHIFT 1 ** 1 $21.77 $21.77
5EB-18513-00-00 FORK, SHIFT 3 ** 1 $21.69 $21.69
5EB-18540-00-00 SHIFT CAM ASSY ** 1 $69.74 $69.74
90149-06285-00 SCREW, BEARING HOUSING*** 2 $0.78 $1.56
90150-05039-00 SCREW, ROUND HEAD ^ 6 $0.72 $4.32
90501-064L1-00 SPRING, COMPRESSION * 4 $0.18 $0.72
90506-13535-00 SPRING, TENSION, DETENT (why not?) 1 $0.52 $0.52
93440-25084-00 CIRCLIP, MAIN AXEL *** 2 $2.98 $5.96
93440-28062-00 CIRCLIP, DRIVE AXEL*** 3 $2.14 $6.42
95824-06020-00 SHIFTER BOLT, FLANGE 1 $0.32 $0.32

Total: $216.66

here is a bare bones list

93102-35423-00
90215-21022-00
5EB-15451-00-00
5EB-13414-00-00
5EB-15456-00-00
5EB-15461-00-00
5EB-17221-00-00
5EB-17261-00-00
90506-13535-00
93440-28062-00 - Three of these are required

total about 130.00

 

here is a bare bones list

93102-35423-00
90215-21022-00
5EB-15451-00-00
5EB-13414-00-00
5EB-15456-00-00
5EB-15461-00-00
5EB-17221-00-00
5EB-17261-00-00
90506-13535-00
93440-28062-00 - Three of these are required

total about 130.00

Thanks a ton for the item fiche. Two more questions, if you would;

Can I pull the gears out separate from the engine or must I break it down completely and 2) would the gear replacement ultimately be better than a new engine all together if the bike has 24k on it?

 

I'm not wanting to put a lot of work into the bike

That kind of sums it up. Splitting the case is by anyones standards "a lot of work"
I did mine this winter and it was almost $300 worth of parts and 12-16hrs wrenching and fooling around (I rebuilt the forks and some other minor junk).
Use 03-05 gears and don't expect to get paid for your labor when you sell,

 

I'm confused, are the 03-05 gears superior in some way to the 99-02 gears; and if so, how?
And yeah, I'm not really expecting to get payed, but I'll have to pitch some cash to my friend who's helping me. That or a case... Which ever he wants more, I suppose.

 

There are several How-To threads that explain exerything verry well. If you read them, gather ALL the parts needed and you or your friend is mechanicaly inclined, two guys cracking the whip should have it done and running in a day (Drink when your done lol).
Second edit HA! Print the pages from the service manual with torque specs and exploded view of the tranny.

 

Ah! Reading material, perfect.
I suppose I really should have thought of that myself, but I'm searching now.
Thanks again!

 

The difference is the number of dog bones on the gears. The 03-05's have an added dog bone. The whole 2nd gear issue is the dogs wearing down and not staying engaged. It will all make sense if you crack it apart.

 

It makes sense to me, I just wonder what would be less work. Me cracking the case and fixing it by hand or simply replacing it with a new engine.

 

Your dammed if you do and dammed if you don't...

You can buy another motor and spend up to $1000 (and hopefully have a clean functioning trans) and have it bolted up and running in 1-2 hours. And than try to dispose of the old motor..sell off or scrap.

or

spent a few hundred dollars in parts and a weekends worth of work and have it working perfectly with no second motor to dispose of.

Your probably better with option # 2 (cheaper) but could...I stress could pull off option #1 for free if you happen to part out the motor and get exactly what you paid for the replacement one.