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Re: I have 2003 yz 125 it runs teriffic and shift's grate...
Well - you will first have to buy an earlier model to get into 6th gear. The 2003 YZ 125 is a 5 speed transmission. There's nothing wrong with your bike.
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If it does stay in gear when barely throttled but does not stay in while under load, the engagement dogs on the gears(inside the engine) are bad and the engine will need to come apart to repair it.
I am presuming you are giving the gear lever a positive shifting motion when changing gears.
If the gear lever is completely tight on the gear shift shaft and the toe of the lever does not touch the engine sidecover when changing up, you may have a worn roller shift lever or loose screws holding this mechanism in place. See the exploded view diagrams of the SHIFT CAM and SHIFT FORK with all part names and numbers on the link below.
Cheers!
When you say "main clutch casing" do you mean the right side cover for the gearbox or do you mean the primary driven gear (AKA "clutch basket") that the clutch boss (AKA "clutch hub") and all the clutch plates fit into?
If you mean the right outer casing > they are slightly different, '97 pn 4JY-15431-10-00 and 2001 pn 4JY-15431-12-00. The entire clutch is the same from 1997 through 2001.
How much was it smoking previously? Too much smoke (oil) is a whole lot better than not enough smoke (oil). If you are mixing the oil and gas then cut back on the mixture. Obviously it is out of balance. Put 1/2 gallon of raw gas in the tank to cut the mix. After a tank or so you should get the balance back.
You need a new shift shaft and probably need a new shift lever due to the bad splines. You can try the JB Weld but I suggest that you go ahead and drill the lever an shaft then put in a cold roll split pin from the hardware store. You have nothing to loose since the shaft and the lever are already toast.
Well. I'm a motorcycle mechanic and my 2004 RMZ 250 recently did the same thing, The Shift forks inside my transmission actually bent and were not moving the gears as far as they needed to go and eventually got to where it quit shifting all together, recently also repaired a CR 125 That wouldn't shift at all and it was the shaft the shift forks go on was bent and hung the shift forks. Sounds like your shift forks are bent to me though.
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