I have a 2004 Yamaha YZ 250 (2- stroke) that is in need of repair if I am to continue riding it, or if I want to sell it (the right way- by fixing it first- and not screw someone over) I used to be a super skinny tall guy and the bike was aperfect for me off-roading in the deserts or motocross track, but its time for a 450 R or X. So anyways.... I think my shifter fork between 4th and 5th gear is damaged and every time I shift into 5th gear, it makes a funny revving up sound and doesnt feel like its engaged; basically making my 5th gear unusable. My clutch is also on its way out, and I need to replace that. I think the clutch basket is ok, but the clutch plates need replacement. Now, if Clymers made a manual for an 04 yz250 (2 stroke), I could do all that myself, since I know how to work on 90% of my bike without a manual- I just dont know the specifics of cracking the case, finding problem areas, and putting it back together. I also dont know how to replace busted fork and/or shock seals, which is another thing i need to fix before i try to sell it or ride it again. Love the bike, but I'm at that point where I either need to seriously replace some things in order to ride or sell. I absolutely will not sell a p.o.s. to someone, as it has happened to me. Any help is appreciated. I'm trying to steer clear of dealers due to high cost. Thank you. -Jesse H [email protected]

SOURCE: 1st gear issues

How do I put this? Yes, you have a bent shift fork. And, yes, they can get bent in a fall, a dump, a drop or whatever terminology is used. The fork engages into a collar on a gear that slides left and right, (slider gear). Large "pins" called "dogs" are cast into the side of the gear. The dogs engage into holes in the side of the gear you are shifting into. Question: What happens if the bike drops on the clutch side and the shift lever is forced down, moving the slider gear to engage first gear even though the holes in the side of first gear are not lined up with the dogs on the slider gear? "You get a bent shift fork" is the correct answer. The force of the shifter lever moving the shift fork into the solid parts of first gear, (not lining up with the holes), is easily great enough to bend a fork. That pressure has got to go somewhere.

The repair means removal of the engine and a complete tear down of the engine/gearbox. The replacement of the bad fork is a given. But I suggest you do some preventative maintenance now, while the engine is apart anyway. Replace the sprocket shaft left bearing and seal, both crankshaft bearings and seals, shift shaft seal and the water pump seals. These are pretty low cost items and replacing them will mean you have pretty much rebuilt the engine. Have the dealer check the shift shaft to be sure it does not now have a bend in it.

Go to the site below where you can see a parts diagram for your specific bike. You will select the actual brand, year, model, etc., once you go to the site. Part numbers and prices are also shown. You can order parts from this site. In the event no price is shown on a particular part, the part is not in stock. http://www.babbittsonline.com/pages/parts/viewbybrandand/parts.aspx

Go to this site and you can download a free PDF service manual.
http://www.carlsalter.com/motorcycle-manuals.asp Most of the manuals are in English but some are not. There is no way to be sure without doing the download. You can always delete it if in a foreign language.


By the way, you can click on an experts name and see that persons profile.
Best wishes, tombones49 Please top rate this solution. Thanks!

SOURCE: I would like to know how to rebuild a gas / oil

Try EricGorr.com Dirt Bike service manual is great. It will explain all that you will need to know about dirt bikes servicing your suspension and the complete bike tear downs. It cost about 20.00

RaceTech.com has all of the tools you will need. Get ready to spend some money though these are specialized tools so they are expensive but they will save you money in the long run.

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SOURCE: Dirt Bike Shifting gears problem(1972 yamaha dt 250 2stroke)

it will be down to adjustment, there are 2 ways to adjust one close to the engine casing and one at the lever just have to get a good balance :)

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