My mechanic gave me a price of about $3000.00 parts and labor and the labor was the killer. So I went ahead and swapped out my engine with a 91 engine the pipping is a little different and it makes my reed valves chatter a little but it runs great and I am happy. If I were you I would swap out the engine with a 96 or above it takes care of the 4th gear problem and cheaper ...Dave
I too had the 4 gear issue. I didn’t even consider having it fixed. I purchased a new engine and swapped it myself. If you click on my name to the left and choose “More post from …” you would find some posts referring (to some extent) to the process – hiccups I had in my swap.
Yes… a 96 engine and above. If you decide to fix it, and once you have it torn into, you will find extra things you will need or want to have done. The cost gets greater and greater. Then you can’t stop. You’re in too deep.
Get yourself a good engine, clean it up and put it in.
I did the repair myself on my 94. You can read my article about it in the workshop section of this website. I think I only spent about $600 for parts. Its not necessarily true that once you tear it down you want to start fixing more and more things. As long as your bike was running good there is nothing else to fix. just treat it like it is a repair only. I rather enjoyed the whole thing.