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The Curse of the Suzuki Gearbox Strikes Again (250)

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Ok ,, today my gearbox gave up on my 06 250 , first of all I thought that some teeth were mishing from the front sprocket ,thats what it felt like , but it only did it in 3rd gear . Then i realized the gearbox was toast .I'm going to split the engine myself , what do you think i will need to replace ?

Edited by wato

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if youre splitting the cases, might as well do it all. i never half ass anything when doing a full teardown, saves me the headache later. do it right, do it once.

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if youre splitting the cases, might as well do it all. i never half ass anything when doing a full teardown, saves me the headache later. do it right, do it once.

+1 on doing it once. If it wasn't done before, I would rebuild it completely. Crank bearings, rod and bearings, piston, and whatever the tranny needs.

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See if you can get a DRZ semi-wide trans and let us know if it will work; rumor has it that it will as Team Suzuki did so in the early 2000s.

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My motor from my 06 is in the shop for the same thing. Tranny is toast. I'm getting everything replaced so I don't have to worry about it.

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Did my tranny twice....... becuase I cheaped out on the bushings washers and most importantly the C-clips. The c-clips are a one time use item like a gasket.

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yep any time the tranny is out i usually replac every bushing, washer, c clip and most of the time i replace 2nd and 3rd gear, and forks if necessary.

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