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It sounds to me that for some reason the gears were not being engaged all the way or whatever holds them in place when engaged had some slop in it allowing the gear dog and slot not to be able to stay in place letting it slip out away from each other during heavy load conditions. Meaning this problem might have been caused from something not being put back together right after the first tear down and repair. When I go to pick up my 05 Foreman 500 from the Honda dealer for the clutch recall I will ask them if they have had any 500's brought in for this problem.
 
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