I have a 97 200 and the bike won't shift up or down. It would get stuck periodicaly the last two rides I went on but I could always get it working again. This time I can't get it unstuck. If I have too split the cases how difficult is it to do and what might be wrong with it. Any help would be great.
Thanx
braden

It is very difficult to split the cases. take it to the shop.
If any of the transmission bearings are worn out then that could cause a misalignment which could cause it to bind.

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mate, pull off the right side cover and check the shifter spring. Mine did something similar and the spring was broken. It's simple to replace. Get a manual to see the exploded diagram.

Cheers,
Andrew

If it's not the spring, STOP RIDING! You will do much more damage. I had my KIPS pin break off the shaft inside the motor and bang around a bit. It started with me being stuck in 3rd. I kept riding and did all kinds of damage. My mechanic said the pin had almost been forced through the case. If I would have stopped riding my repair would have been much cheaper, instead I needed 3 new gears and a shaft. While it's apart, you might as well have the shop replace all the seals/bearings in the bottom end. I took advantage of my misfortune by sending my entire engine to Jeff Fredette ( www.frpoffroad.com ) and had him do the repair to the bottom end and replate/port my cylinder and do the topend. The bike now screams!

I bought a used CR250 once and the same thing happened to me...

When I changed the tranny oil, the drain plug (obviously not the original) had several thick washers on it. When I put the drain plug back in, I only used one copper washer to seal.

It took me a while to figure out that the drain plug was too long and was hitting the shift drum in the tranny. That's why it was stuck in gear!!

Thanks for the replies. I will probally go ahead and take the the cover off the right side and check everything in there. If I don't find anything obviously wrong I will go ahead and pull the engin and mabye tear down the top end to cut down on shop costs if I end up taking it to one. What kind of special tools are needed to split the cases? . How much harder than a top end is it? My dad and I are both fairly mechanical we have done several top ends on a yz and i've done one on my kdx.

In my opinion, its not really that hard to split the cases. Make sure you keep all the parts organised really good in a big tray of parts, makes it MUCH easier!
The only special tools you'll need are a flywheel puller, about $10 at the dealer, and I made a puller (more of a "pusher") for pressing off the left hand cover off of the crank bearing. It was a 2x6 block of wood, with a hole in the middle (lines up w/crank) and 5 holes that match up with the ones around the magneto. Bolted the block up to the case with extended bolts. Then put a large (M12 or M10) bolt through the hole, up against a nickel siliconed to the crank as to not damage it. A large fender washer went over the bolt on the other side, then held a nut against the washer. Holding the nut and turning the bolt presses against the crank, pulling the case off with a few loud snaps.
Once the case is off it should be pretty easy to see what the problem is. Shifter forks on the KDX seem to wear out/bend pretty easily, take a good look at that. Look at all gears, see if they are siezed to the shaft/bushings, look at drum shifter/slider pins etc.
Puttin the case back together is easy, just slap all the stuff back into the left case first I think, then line it all up into the right case. Then put a large socket over the left side crank, put the magneto bolt through that and tighten it down (make sure you use some yamabond to seal the cases back up FIRST, I forgot to do that once!).

Not too hard over all, just takes some time. :thumb:

what's KIPS?

I took the right side cover off and the first thing I saw was a bunch of little metal fragments . After looking it over more I realized that the pin thing that screws on to the end of the power valve shaft was broken off. In my service manual its on page 5-3 and it has a 4 pointing to it. I asume thats what the fragments are from. This just came to me while typeing this I don't think it the gear was stuck I think the little c shaped thing thats on the end of the shift rod is stuck back not allowing it to hit the knobs to switch gears. Because it will shift up or down from neutral but after that the c shaped thing misses the the little knobs. From the pics in the manual it doesn't look like it is not sticking out as far as it should. Does that sound logical to any of you guys? If that is the case do you guys thing I will need to split the cases? Are there any good ways to flush out the trans? By the way all the gears on this side of the trans look fine.