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Found 78 results

  1. taking my transmission apart of my 2013 kx450... bike has about 40 hours on it. started grinding and jumping out of gear when shifting from 4th to 5th under load. after splitting cases and inspecting gears, i was surprised to see they all looked like they were in nearly new condition. the only wear i can find on any of the components is on the 5th gear gear dogs. they arent a perfect 90 degree angle anymore, but i wouldnt say they are anywhere near "excessive" wear. i guess my question is.. how much wear is too much? i know these are incredible precise parts, but it's just hard to imagine this is what was causing the jumping out of gear. but on the same note, there is NOTHING else wrong that i can find so it almost has to be this?? ive provided some pictures hoping someone with more knowledge and experience with these transmissions could set me straight. sorry if this posting is in the wrong place, but this is the first time ive ever joined a forum to ask a question. Anyway, thanks to anyone who can help. James
  2. i recently bought a 2002 ktm 520sx the crank was gone so i had to split the motor. while its split i would like to add the 5th and 6th gears in there just the wide ratio for top speed.i have seen the parts list for about 250 but when i called someone just quoted me 700 for parts. not sure why such the big difference. looking for any help with this. also if anyone has directions for this would be amazing. thanks again for the help
  3. I have a 2003 yz125, it’s excessively dripping oil out of the silencer and where it meets the exhaust, there’s a lot of oil, it’s throwing out huge amounts of smoke and starting to foul out plugs. I’ve already replaced the clutch side seal (I’m almost positive it’s coming from the transmission oil) and repacked the exhaust. After that it seemed to stop or at least slowed down. After sitting for a couple months I changed the transmission oil once again and started it up, I let it warm up and didn’t feel like it had the normal amount of power and kinda bogged down, we revved the hell out of it and it cleared up and felt normal. We loaded up and drove out the the desert and I started it with the choke on and let it idle, after about a minute it died and wouldn’t turn over at all. We came back home and took out the spark plug and it was fouled replaced it and it ran again. The next day the same thing happened. Any thoughts on what I should do? The engine was recently rebuilt and I only use it for trail riding and run about a 40:1 ratio. Thanks
  4. These are pictures of a 2006 honda crf 250 right side case half. In the kick starter mechanism housing, there is a small piece of aluminum that bridges across a hole in the case. It broke off, and im wondering if anybody else has seen this before, and will it be an issue? I dont think it serves a purpose, but i would like a second opinion. Thanks!
  5. Was wondering if anyone knows of a diagram that shows the thickness and inner diameter size for each washer. I think I have it right but I want to be sure. And does it matter what direction the washers face? I'd imagine it does being that each thrust washer has a smooth edge and a sharper edge. I face the smooth edge of the thrust washers outwards if you know what I mean because if they are the other way around it wouldn't seem right. If anyone that has experience with this stuff can chime in that would be awesome
  6. I replaced the transmission on an '05 kx85, and ive put the cases back together and everything spins freely, it shifts through all the gears, but once you put that tensioner thing that presses on the shift drum (dont know what the part's called) you cant shift into 3rd, itll get stuck halfway between second and 3rd, but once you take off that tensioner thing you can spin the drum and shift through all the gears just fine, whats going on?
  7. Please this post is not asking what I should use(that is beaten to death!) but can I use the stuff in the pic for my tranny. I use Belray 80w Gear saver and perfectly happy with it. I uploaded this pic to a fb Yamaha page and almost got my head ripped off when I asked if I could run this in my YZ250X Transmission. "Different additives" "not designed for it" you stupid fk" Use what the manual says...….my manual says 10-40 soooo is there a difference between 10-40 for my tranny and the 10-40 in the pic??? I bought this oil for my RMZ250 that the X is replacing and wanted to use this if I can as opposed to give it away...some say yes and some no. I get better advice and less attacks at TT than FB...jeesh Ill never ask another tech thing again on FB...
  8. My 2001 yz426f has a missing 5th gear, what i mean is whenever i shift into 5th the bike revs out like a false neutral and goes nowhere. I still have all the other gears 1st-4th but 5th won’t go, I like to use my bike for wide open runs through everything, but randomly without any noise or jerk or anything it just wouldn’t go into 5th . I was wondering if their was anyone that could help or point me in the right direction. I know theirs not many of these bikes left but i thought i’d give it a shot to put it out their and see if anyone could help?
  9. Was out for a short ride today to try out my new proshotcam gopro mount and on the way back, close to home luckily, the bike (2015 yz250f) acted like I accidentally clicked it into neutral. Thinking this was the case I pulled in the clutch and clicked down to first, and went to start going again and it revved with out moving, or barely moving if that, hard to tell I was in sand. So I shut off the bike and while there I tried to click it into a different gear or neutral which didn't work the first couple tries then it did but felt different than normal. When the bike was in gear it could be rolled without the clutch in but made a funny noise coming from the tranny area. The bike seemed fine in neutral so I started it. It idled fine and revved fine, all normal noises. Then upon clicking it into gear it started to make a funny noise in the tranny area again so I just shut it off right away. So it shifts into gears fine but will not engage the engine and the wheel, so it won't drive. I'm going to split the cases and see what the problem is, but was just wondering if anyone had any idea. Something wrong with the gears, shift fork, shift cam, or did the tranny bearings go? Thanks
  10. Preparing my 2011 KTM 250XC to convert to 300 XC-W, big bore kit... but more difficult is the transmission. Looking at the catalog it seems to me that to change the gearbox from XC to XC-W wide-ratio is about the changing: 1. Main shaft T=14, 54833201000 2. Idler gear 1st T=32, 54833211100 3. Idler gear 2nd T16, 54833202100 4. Idler gear 2nd T=26, 54833212100 Is there anyone who has done this successfully?
  11. I’m looking for some opinions on a noise my bike is making. When shifting into first from nuetral my bike slams into gear which is accompanied by a “ping” noise that sounds like 2 swords hitting each other. I can faintly hear the “ping” noise ringing out while rolling around in first gear. Upshifts are all smooth however downshifts seem to slam pretty hard from 3rd to 1st. I have also found that while shifting to nuetral while stopped with the bike running, my gears will grind and not allow me to shift to nuetral. This is only on occasions. Any ideas? All new clutch last year with forged clutch basket. I did notice my chain was pretty loose on this last ride, which I have head can cause noises and hard shifts. However that “ping” noise sounds like it’s coming from inside. Any advice is appreciated.
  12. I’ve read the manual, it says warm the bike up for 3 minutes and then let it sit for 3 minutes and check to see if oil comes out from the check bolt. When the bikes been sitting for a while and hasn’t been running oil just drips out of the check bolt. I’ve heard that as long as it drips out when the bike is cold it should be fine. If I do what the manual says and warm the bike up for 3 minutes and let it cool down for 3 minutes no oil will come out of the check bolt. If I top it up until it comes out as the manual says when I let the bike sit overnight the oil will come out of the bolt real fast. Does this mean it’s too full? If someone knows anything about this or have a similar bike let me know. Thanks :)
  13. My son and I just finished rebuilding a basket case 1978 yz 80, we got it as a rolling frame and two milk crates of parts, some of which were for other bikes. We used a Clymer manual to help with reassembly. Since we did not do the disassembly we had a lot of "holes" in our knowledge even with the manuals help. This was our first complete engine rebuild. We have it back together, and it runs great, EXCEPT it drops out of gear, 1st and 3rd at random times while under load. Could this be caused by missing shims/ washers, or just used worn parts. All bearings and seals were replaced, and the transmission gears all looked good and seem to shift nice. The manual mentioned that there could be shims, but there was none shown on the diagrams, however we have a few washers/ shims ? left over, which could be from our bike or some other bike, but we have no way to know. Before I pull this motor apart I want to know where to start with diagnosing this issue. Thanks
  14. I am rebuilding a 2002 CR250. I may or may not have gotten the gear on the end of the tranny mixed up. 50/50. I need a diagram for a 2002 CR 250. Someone have a manual they can scan that page out of? When I look around I cannot find the exact one online
  15. 2006 YZ 250.. The manual calls for 10w30 (yamalube 4 stroke oil), can I use 10w50 (Motul semi sythetic 4 stroke oil) ?? I bought the bike, want to change the gear oil before I ride tomorrow but all I have at the moment is the Motul 10w50 semi synth. Is that oil going to be too thick compared to the 10w30 or will it be fine.. Thanks
  16. Hello I currently own a 2002 cr 125 and I believe i have a seized tranny. I have come across a 2000 cr transmission for sale near me. I am wondering if anyone knows if they are interchangeable. Thanks for any help
  17. Hello all, I have an issue with my 2012 crf450r. The bike runs and drives great, but 2nd gear is making a noise that sounds a bit like grinding/chain slap. This only happens in 2nd gear, the rest sound normal. I am wondering if anyone has had this issue, or if anyone knows what causes this problem.
  18. BTW, I'm new to two strokes, haven't had one since I was a kid and dad did all the work. Ok, so I've searched and not found what I'm looking for so figured I'd ask here. Recently picked up a 2000 yz250 that supposedly has a 295 or 300 big bore kit. It ran strong so I didn't fret too much over the little things. Paid $1500 and took it home. Drained the gear oil and it looked a bit odd to me. I refilled with Rotella, ran it for about 15 or so minutes out back. Drained and it looked the same. ? Could this be water getting into the oil? Read somewhere that it should look like this but seems odd. Any help would be appreciated!
  19. Hey guys, Backstory: 2010 RMZ 250, bike always ran and shifted great, no false neutrals, everything was fine and good serviced. Did another rebuild recently (3rd one so far). New Rod and athena 290 bigbore kit this time. Gearbox looked fine upon inspection. Bike started, ran and shifted great after rebuild. So, here's the problem now: after a few laps, the bike started sputtering and clonking in 4th gear and only in 4th gear. 1st, 2nd, 3rd and 5th had no issues at all. The sputtering felt like a fuel problem, it just won't rev up. When i was trying to figure out what was wrong, the transmission locked up in 4th gear on the bike stand. Sure enough i ripped the whole engine apart again and found a broken shift fork (the one for the 5th gear). Everything else seemed good. So i installed a new shift fork and inspected the other parts. Bike starts, shifts smooth and sounds good. Rolling in all gears is no problem. But again, the 4th gear sputters under load. And that's where i am now. Going to open the engine again. But maybe somebody has an idea what's causing my problem. Seems to make no sense to me. Mike
  20. Bought new in 1997, my Suzuki DR650 motorcycle in 2014, with 20500 Km on the clock experienced unpredictable catastrophic 3 rd gear disintegration. Eventually in December 2016 the Small Claims Court of South Africa, with Suzuki Auto South Africa defending,the court awarded me my damages claim for the repair of my Suzuki motorcycle. For more details visit www.harryterezakis.blogspot.com
  21. I recently bought a 2005 yz250 on the first ride about 5 minutes into the ride my bike would not shift anymore nothing I did would make it shift engine still ran fine it is just stuck in 5th any help or suggestions would greatly appreciated
  22. Hello all! thanks for the awesome recurse that this site is and all of the help this place already has been before this...my first post! So, I am as the title states, rebuilding the lower end of my 2008 xr650l. Now that I have installed the 2nd and 5th gear mod as well as replaced another worn gear, and center shift fork I now have the shift drum installed and am beginning to wonder if there is indeed a way to install that(shift drum) backwards? I have tested and all seems to shift smoothly through the gear, however it would seem to me that if i were on the bike I would be pushing the pedal down to shift through the top four gears. Is this possible, or am I just second guessing myself? THanks for the help!! -Jdoo
  23. Hello I want to order a 2016 gearbox but I have a question. Does a rmz 250 2016 gearbox fit in a rmz 250 2015 engine ? because I have always have problems with the 15 gearbox and the 16 gearbox is much better i have ask 6 local dealers but they think it fits but nowone nows it for sure do anybody can help my ? Greetings Rens
  24. Hey everyone, I picked up a 2004 RM125 a while back and did a lot of work to it. Its running great now. However, the only problem I cant figure out is this: every time I shift from first to second, only while under load, the bike hits neutral. This happens while shifting down too. It feels almost as if neutral is a normal gear, comparable to that of a numbered gear, and the bike shifts into it as such. While the bike is stationary or off I can shift between first and second no problem which leads me to believe it isn't a transmission problem? I'm currently running Ecstar 10w-40 per the manual. Should I try a different oil? I've adjusted the shifter position and ensured it is tight. What could the problem be? Any help would be appreciated. Thanks!
  25. Pulling into work today my bike stopped being able to downshift. I tried to downshift from third to second and the shifter didn't come back up (it stuck down) so I tried up shifting instead and it worked. It shifted flawlessly all the way up into 5th, but now won't downshift. Things that might help speed the conversation along... - The bike is running fine otherwise and not making any strange noises. - Rolling forward and back doesn't change anything - Pushing in and out on the lever while trying to downshift does nothing. - The lever swings down freely, all the way to the frame, and is returning to its rest position. There is just not the usual click of the gears changing. Anyone have any ideas? Thanks in advance.
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