2001 kx250 only 3rd gear works all other gears lock up and shut down motor

[motoshawn]

Hi there. I have a 2001 kx 250 , so my problem is the motor starts and runs good and third gear works good but the transmission won't go into neutral, and 1st,2nd,4th,and 5th lock the bike up. Has anyone else ever have this problem.

[DBMX 925]

It's time to split the cases and see what's up.

[youngztr]

Are you saying the bike is stuck in third gear and won’t shift out of third or into any other gear including neutral?

[KDXGarage]

Time to split the cases.

[motoshawn]

The transmission shifts through the gears fine. But won't go into neutral. I can ride in third gear just fine. But if I change to any other gear. The transmission locks up and the engine. But I can pull the clutch in and keep the engine running.

[Blackwoodz]

Did this happen all of a sudden or did you just rebuild the bottom end?

[motoshawn]

It just happened out of the blue.

It just happened out of the blue.

It just happened out of the blue.

[youngztr]

It sounds like the gears are not aligned properly.  Shift fork problem, a broken clip, bent/cracked shaft.  Time to open it up and take a look inside.

[Blackwoodz]

First thing I would do is take the clutch side case cover off. Check to see if everything is normal and that the shift drum is securely in place. If that all good you have no other option but split the cases and see whats going on. have you drain the tranny oil to see if any large debris comes out with the oil?

Edited August 20, 2014 by Blackwoodz

[lethalweapon100]

Split-a dee cases!

[motoshawn]

Looks like in need to buy some new tools.

[no1clyde]

Look in the FAQthread above, I put a case splitting thread in there that may be a help to you.

 

Ed

[greenteam05]

motoshawn, I know this is a super old thread, but I am having the EXACT same problem on my 01 KX250, I am planning on taking the engine out today, what did your's end up being?

[motoshawn]

On 10/17/2017 at 8:59 AM, greenteam05 said:

motoshawn, I know this is a super old thread, but I am having the EXACT same problem on my 01 KX250, I am planning on taking the engine out today, what did your's end up being?

I just pulled it apart and everything looks good but still locking up. What was wrong with your? 

 

[KDXGarage]

You answered him three years after he asked you a question that he asked 3 years later. I love the internet. I hope you all get your bikes situated.

[Jeekinz]

I saw that and shook my head, then just hit the back button.

[Motox367]

Might have a gear seized to shaft or broken hear something like that. Glad you're finally getting around to it ? just noticed it's been broken awhile

[motoshawn]

Yep 5th gear is stuck on the input shaft.   Anyone have a transmission for a 2001 kx250. 

[Motox367]

11 minutes ago, motoshawn said:

Yep 5th gear is stuck on the input shaft.   Anyone have a transmission for a 2001 kx250. 

Look around on eBay I think tranny was same for while. Turbodan probably would know exact years

[motoshawn]

Yep and that gear is the same from 1994 to 2001. Gotta get the old off and see if I need a shaft too.