04 yz250 5th gear issue

[Jessup]

just recently finished rebuilding a yz250 i got off a buddy got it all jetted today running pretty good ,problem is in 5th it feels like the gear in engaging in and out,ive read up on this problem my friend had cases split to try and fix this problem before i got the bike he replaced 2 shift forks and the shift cam and its still doing it.I am fairly confident it is the dogs on the 5th  gear only problem i have is i dont know exactly what all i need to order to fix this issue.I have looked at the diagram for trans and have no idea which parts i need to replace.just the gear with the dogs or also the gear that goes with the dogs,and also dont know which shift fork is for 5th and if i should replace that also while i am at it.if some one could help me out with part #'s of the parts i should need that would be great.

[SachsGS]

5th gear and the gear that engages 5th will require replacing, may have damaged the new shift fork as well. Yamaha transmissions generally use very few shims, did you check the shafts for end play during reassembly? 5th gear will be the largest gear on the clutch shaft.

[Jessup]

ok thanks i will order those two gears but which shift fork will i need its only been rode for maybe 1hr since it was done and i only tried 5th a couple times to see exactly what was going on but i will order the fork just to be on the safe side even thopugh there is a new one in there.

[SachsGS]

The shift fork in question will be moving a gear that engages with 5th gear. This engagement is accomplished via engagement dogs and if you examine the dogs carefully you will probably find them rounded off. These two gears are the ones in question. When the dogs are damaged engine torque will try to disengage the gears and force the shift fork against it's slot in the sliding gear thus damaging both parts. As mentioned before, with the transmission assembled in the cases, examine both transmission shafts for lateral play - it doesn't take much play for the dogs to not engage sufficiently.

[Jessup]

thanks for the responses i am almost 100% positive it is the dogs i will be splitting cases i know what gears i have to order i just need to know which one of the 3 shift forks is the one which is used on the 5th gear and i need to replace.

http://www.yamaha-motor.com/partviewer/default.aspx?ls=sport#/Yamaha/YZ250_-_YZ250S1_-_2004/SHIFT_CAM_FORK/YZ250S1_(2004_MOTORCYCLE)/SHIFT_CAM_FORK_(YZ250S1_-_2004)

is it 11,12 or 13 im having a hard time figuring it out on diagram

http://www.yamaha-motor.com/partviewer/default.aspx?ls=sport#/Yamaha/YZ250_-_YZ250S1_-_2004/TRANSMISSION/YZ250S1_(2004_MOTORCYCLE)/TRANSMISSION_(YZ250S1_-_2004)

im going to order gears 3 and 15 off that diagram,and also a new clutch pack and cable just because.

[SachsGS]

Check the part numbers, sometimes the same shift fork is used more then once. Your local Yamaha dealer parts guy should be able to identify and order the correct parts.

[Jessup]

local yamaha guy knew less then me this is the same dealership i bought a brand new zx10r from and they did'nt want to throw in a key chain lmao.i figure i need the 5th and 3rd gear pinion and 2nd fork i found a guy who had same problem and replaces these three parts and its all good now.the bike went to the dealer in pieces for this same problem my friend was told to replace 2 shift forks and shift  cams and did not fix problem

[arnego2]

I would hunt for a complete gear box of a YZf400, YZF426 or YZ250 on ebay, should cost you about $100 and you can do the work yourself. Tools could cost you about $ 70 or so but once you got them you can do almost all work yourself.

[SachsGS]

It's a shame your local dealer can't repair the products they sell. I would hunt down a wrench who knows what they are doing and have this individual examine the gearbox carefully. Since your bike has already suffered one botched repair job it is imperative that every component be inspected and accounted for, this is beyond a "cyber space" solution (I can only,hopefully, point you in the right direction). Good luck.  

[Jessup]

im just gunna order everything that could cause this issue and replace dont wanna split cases again that for sure