Question about 2003 Yamaha YZ 250

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Iv got a 01 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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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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I have the same problem. on the passenger side under the fender you will have access to the transmission. Remove the cap on the end. You will need to drain the transmission fluid and replace all the gears in the end cap if damaged hopefully they are not and you can just tighten up the nut. What happens is a nut comes loose and backs off the pressure on the bearings and you loose 5th. I removed the entire transmission and opened it up. There is nothing wrong with the other gears, because your problem is with the 5th gear synchronizer assembly. I let mine go too long and I'm having to replace everything. Make sure you put the appropriate torque on the nut and hit it with a hammer to lock it down. This should really be designed with a different method of keeping that nut in place. It's costing me lots of time and now money at the stealership. Good LUCK.

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