The issues
Countershaft
Seal
Crankcase
Vent
Grease Cable
Routing
Oil
Level
Fender Thermostat
Linkage Fork
Oil
Plug
Wire
Sag Kickstarter
Bolt
RH Footpeg
Bolts
Clutch
Bushing
What's the issue?

The issue:

This problem plagues all years of BRP's. It's almost a guarantee you will see it, my '00 took 2 years, but it finally did it. The unit distorts and the guide pin comes from it's holder, jamming everything open. It's another issue that is not a drastic problem, but more of an inconvenience.


The Fix:

The fix here is an easy one. A lot of the guys just remove it, but Honda put it there, so there's a reason. You don't want the bike running too cool, as that will accelerate cylinder wear. The better fix is to throw in a Napa thermostat #115, MotoRad for a Suzuki Swift, or Carquest #31978. These are meant for small GM cars. It's an almost drop in fix. All you need to do is drill a small hole in the outer ring of the 'stat to allow fluid to flow when it is closed. This is a must do to prevent hot spots in the engine.

More cooling info can be found at The FAQ Page.