im needing to replace a transmission fork on a 91 250x. Do i have to tear down the engine or is there a way to replace it without tearing the engine down.

 

You have to split the crankcases .. What makes you think you need to replace 1 of the shift forks..?

 

cause i downshifted too hard and now its stuck in 2nd gear. I took it to 3 different shops and they all said the same thing. That one of the forks are probably bent.

 

Transmission problems on the 250X and 300EX engines are commonplace now that they have seen many years of use. It's not just the 1987 models anymore. I've been into several myself just in the past year alone.

For your benefit, I hope they are right and it IS a bent shift fork. That does require tearing down the engine but it's not an expensive fix.
But in every one of the ones I have been into, the problem has been the transmission itself and not shift forks or a broken shift drum. Most times requiring several gears and/or shafts and bearings to be replaced,..not cheap.

 

well thanks i hope it is simple. But i have seen on ebay where they sell the whole trans set-up for about 100 dollars. I figured i would buy the trans gears and forks used then bearings and what not new.

 

Did the 3 shops remove the alternator cover and check the gearshift assy ...

 

sure didnt. they just got on it and tried getting it to pop out of gear

 

Well the gearshift assy should be checked before anything is done .. If you decide to check it yourself PM your email address and I can email you the alternator/gearshift linkage section ..