My ATC 90 makes noise in the bottom end

[turbowrenchhead]

I took my bike for a weekend camping trip. The second day I went out and when I shifted to second it sounded like the chain kicked off and was rattling around. I checked it wasnt. Shift back into 1st and it was fine, shifted back into second and the same thing happened. I limped back in first. Got it home and tore off the side covers and found nothing but when I turn the shaft it doesn't feel or sound right. Has anyone seen this before. What am I going to have to replace? I have not had a chance to pull the motor and split the case.

[whitetail hunter]

I could be wrong. but it sounds like the shifting fork is bent!

[Mr_RPM]

sounds like your going to need a manual....a big manual..... ;P
i was going to say maybe the internal clutch cover broke (mine did and was making some funky noises. but you said you didn't see anything wrong.)
so you can drive in 2nd just with noises or does 2nd just not work?

if it doesn't work at all im guessing you need to split the cases. i had that happen on a 400ex and had to replace 1st gear.

[turbowrenchhead]

2nd will not go anywhere

[Mr_RPM]

well your either not getting into 2nd (like forks are broke or something) or 2nd is just broken. chances are your gonna be splitting your case.
i just split mine in maybe all together time of 3 hours. but i didnt just focus on my tranny. everything from the axle to the forks to every engine part is all taken apart.
it was like 4 days of just tinkering. so 3 hours of just work would probably get you all apart.
if you have a full clymer manual (its what i have, you dont need it for the disassembly but the assembly.) and you keep organized (my problem) its not to hard. but fixing it might be the hard part.