Question about 2003 Yamaha YZ 250

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Iv got a 01 yz250.it dosent click into 5th gear.All it does is make a clunky noise like its trying to click in but nothing happens.1n234 are algood.anyone know whats happening??

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  • dave_dave_so Mar 15, 2009

    thanks for your help mate..much apreciated.

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  • 3,567 Answers

You have a bent shift fork. The engine will need to come out of the bike then the gear box gets opened up, ( major repair job ), the offending shift fork gets replaced then all gets reassembled. This is not a project for the amature mechanic unless you want to buy a new bike.

Posted on Mar 11, 2009

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1 Answer

Noisy 5th gear


but no there was definitely a loud whirring noise in 5th gear sort of like a very noisy bearing. The bike still ran in 5th but it was definately becomming increasingly noisy. When I changed down to 4th the noise went away even if I slowed to the rev range I had been cruising in 5th. Same story with the other gears, but the noise returned with a vengence in 5th. Needless to say I rode the rest of the way home in avoiding 5th. Any ideas? I suppose I'm looking at a gearbox strip? Could the noise be anything else? ,Had a similar issue with my 1000S, only 5th gear was noisy - a sound like a dry bearing -other gears were silent. Bike had done 70,000kms and serviced correctly. Had Barry from IME check it out. Turned out to be both 5th gears needed replacing - looked like the case hardening on the gear faces was eroding and pitting. New gears went in and the box properly shimmed and happy to say 6000 kms later all still silent in the gearbox department. Plus the added benefit of slicker gear changes.,,,

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