Question about 2005 Suzuki RM-Z 250

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I've lost 2nd gear on my rmz 250 suzuki 2005, does anyone know if you need to split the engine or can you get to the gears any other way?

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Hi,no easy answer i,m afraid,you will have to split the engine,before you pull it all aprt check the shift drum selector rawl pins,if one of those has come out,it will not shift up into the next gear,hope this helps...cheers

Posted on May 03, 2010

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Gearbox oil change on a suzuki rmz 250 2010 model


Is this a 2 cycle or 4 cycle motorcycle?

I am not familiar with this model. Typically, motorcycle transmissions are lubricated with engine oil. Do you not have a owners manual for your 3 year old motorcycle? Check behind the side covers or better yet, check with your Suzuki dealer.

Thanks for your interest in FixYa.com

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You broke the gears in the transmission, or have a bad shifter fork.

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Oct 25, 2011 | 2005 Suzuki RM-Z 250

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The bike has a slightly bent shift fork. The repair requires a complete engine teardown. Special tools needed include a torque wrench, impact driver, flywheel puller, and case splitter. This repair is not recommended for the novice mechanic. There are a lot of parts involved and just one mess up can force you to take the engine in a basket and plead with the dealer to reassemble the parts. The dealer will charge you more to repair a basket of parts than if you had just let them do the repair from the start. Below is a generic diagram showing how the shift forks, ( your bike has three ), move slider gears left and right to engage other gears. Please rate my answer. tombones49_122.gif

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1 Answer

Well the motor locked up and i couldnt kick it at all shifted threw all the gears just fine but i wuz messing with it and i ran through all the gears trying to turn the back wheel and knock it loose didnt...


If you are running 5th gear mid throttle the compression in the motor wasnt enough to push the piston back down

for the record ( i run a ts 250 savage 2 stroke ) i,ve done it my self it happends

try to keep it the power band you will be fine

good luck.

Mar 26, 2011 | 2004 Suzuki RM-Z 250

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Im afraid my 2nd gear is gone. When i shift into 2nd it just clicks/grinds. All the other gears are fine and powerful. What is it?


It could be your shift fork or you have a few broken teeth in 2nd gear unfortunately you will need to split case to see what is wrong.

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One oil filler, check your manual or download one from one of the manual sites on fixya. Quantity is written on crancase generally, or dipstick on filler plug, The oilpump, pumps the oil throughout engine.

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2005 yz 250 shifting problems


Well. I'm a motorcycle mechanic and my 2004 RMZ 250 recently did the same thing, The Shift forks inside my transmission actually bent and were not moving the gears as far as they needed to go and eventually got to where it quit shifting all together, recently also repaired a CR 125 That wouldn't shift at all and it was the shaft the shift forks go on was bent and hung the shift forks. Sounds like your shift forks are bent to me though.

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