Question about 2003 Yamaha YZ 250

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You could have a bent shift fork. The engine will need to come out of the bike. Remove the top end, the flywheel and electrics, the clutch, shift shaft and kick starter and a few other parts. THEN you are ready to split the gearbox to get to the crankshaft, gears, shift drum and shift forks.
You will need an impact driver, flywheel puller, case splitter, torque wrench and factory service manual, plus the normal screwdriver, pliers, etc.. Alternate to the special tools is taking it to the dealer and say "Fix it". I normally tell people to take it to the shop just so they don't get into such an involved project and now they have a knowing eye working on the engine. About $800 to repair.

I would pull the right side cover and check the shift mechanism first. With the cover removed, you will see the clutch and behind the clutch is part of the shift shaft. Move the shift pedal up and down (as best you can) and you will see the arm behind the clutch move a bit. Is it hung up on anything on the end of the shift drum?

Posted on Jun 22, 2009


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