2005 YAMAHA YZ250LC oil

4-45
KICK AXLE, SHIFT SHAFT AND PRIMARY DRIVE GEARENG
EC4C5310
Shift shaft
1. Install:
9Roller 1
9Plain washer 2
9Shift shaft 3
NOTE:
Apply the transmission oil on the roller and shift
shaft.
2. Install:
9Torsion spring 1
To kick axle 2.
NOTE:
Make sure the stopper aof the torsion spring
fits into the hole bon the kick axle.
EC4C5602
Kick axle assembly
1. Install:
9Kick gear 1
9Plain washer 2
9Circlip 3
9Ratchet wheel 4
9Spring 5
9Plain washer 6
9Circlip 7
To kick axle 8.
NOTE:
9Apply the transmission oil on the kick gear
inner circumference.
9Align the punch mark aon the ratchet wheel
with the punck mark bon the kick axle.
4. Install:
9Bolt (shift guide) 1
10 Nm (1.0 m•kg, 7.2 ft•lb)
1P8-9-30-4B 11/5/04 10:59 AM Page 36

4-46
KICK AXLE, SHIFT SHAFT AND PRIMARY DRIVE GEARENG
EC4C5420
Kick idle gear
1. Install:
9Kick idle gear 1
9Plain washer 2
9Circlip 3
NOTE:
9Apply the transmission oil on the kick idle gear
inner circumference.
9Install the kick idle gear with its depressed side
atoward you.
3. Install:
9Spring guide 1
NOTE:
Slide the spring guide into the kick axle, make
sure the groove ain the spring guide fits on the
stopper of the torsion spring.
4. Install:
9Plain washer 1
9Kick axle assembly 2
NOTE:
9Apply the molybdenum disulfide grease on the
contacting surfaces of the kick axle stopper a
and stopper plate 3.
9Apply the transmission oil on the kick axle.
9Slide the kick axle assembly into the crankcase
and make sure the kick axle stopper fits into
the stopper plate.
5. Hook:
9Torsion spring 1
NOTE:
Turn the torsion spring clockwise and hook into
the proper hole ain the crankcase.
1P8-9-30-4B 11/5/04 10:59 AM Page 38

4-51
YPVS GOVERNORENG
4. Install:
9Governor assembly 1
NOTE:
Align the groove ain the governor with the fork
band set the governor in the crankcase cover.
3. Install:
9Dowel pin 1
NOTE:
9While compressing the spring, install the dowel
pin.
9Make sure the dowel pin fits into the groove a
in the retainer.
2. Install:
9Ball 1
9Retainer 2
To governor shaft 3.
NOTE:
Apply the transmission oil on the retainer and
ball.
1P8-9-30-4C 21/5/04 12:59 PM Page 4

4-52
WATER PUMPENG
EC4G0000
WATER PUMP
Extent of removal:1Impeller shaft removal2Oil seal removal
Extent of removal Order Part name Q’ty Remarks
WATER PUMP DISASSEMBLY
Preparation for Crankcase cover (right)
Refer to “KICK AXLE, SHIFT SHAFT AND
removalPRIMARY DRIVE GEAR” section.
1 Water pump housing cover 1
2 Impeller 1
3 Plain washer 1Refer to “REMOVAL POINTS”.
4 Impeller shaft 1
5 Bearing 1
6 Oil seal 2Refer to “REMOVAL POINTS”.
1
2







10 Nm (1.0 m•kg, 7.2 ft•lb)
10 Nm (1.0 m•kg, 7.2 ft•lb)
14 Nm (1.4 m•kg, 10 ft•lb)
1P8-9-30-4C 21/5/04 12:59 PM Page 6

4-53
WATER PUMPENG
EC4G3000
REMOVAL POINTS
EC4G3110
Impeller shaft
1. Remove:
9Impeller 1
9Plain washer 2
9Impeller shaft 3
NOTE:
Hold the impeller shaft on its width across the
flats awith spanners, etc. and remove the
impeller.
EC4G3210
Oil seal
NOTE:
It is not necessary to disassemble the water
pump, unless there is an abnormality such as
excessive change in coolant level, discoloration
of coolant, or milky transmission oil.
1. Remove:
9Bearing 1
2. Remove:
9Oil seal 1
EC4G4000
INSPECTIONEC444200
Impeller shaft
1. Inspect:
9Impeller shaft 1
Bend/Wear/Damage
Replace.
Fur deposits
Clean.
1P8-9-30-4C 21/5/04 12:59 PM Page 8

4-54
WATER PUMPENG
EC444300
Impeller shaft gear
1. Inspect:
9Gear teeth a
Wear/Damage
Replace.
EC4H4600
Bearing
1. Inspect:
9Bearing 1
Rotate inner race with a finger.
Rough spot/Seizure
Replace.
EC444400
Oil seal
1. Inspect:
9Oil seal 1
Wear/Damage
Replace.
EC4G5000
ASSEMBLY AND INSTALLATION
EC4G5111
Oil seal
1. Install:
9Oil seal 1
NOTE:
9Apply the lithium soap base grease on the oil
seal lip.
9Install the oil seal with its manufacture's marks
or numbers facing the crankcase cover (right)
2.
2. Install:
9Bearing 1
NOTE:
Install the bearing by pressing its outer race par-
allel.
1P8-9-30-4C 21/5/04 12:59 PM Page 10

4-55
WATER PUMPENG
EC4G5220
Impeller shaft
1. Install:
9Impeller shaft 1
NOTE:
9Take care so that the oil seal lip is not dam-
aged or the spring does not slip off its position.
9When installing the impeller shaft, apply the
lithium soap base grease on the oil seal lip and
impeller shaft. And install the shaft while turn-
ing it.
2. Install:
9Plain washer 1
9Impeller 2
NOTE:
Hold the impeller shaft on its width across the
flats awith spanners, etc. and install the
impeller.
3. Install:
9Dowel pin 1
9Gasket (water pump housing cover) 2
4. Install:
9Water pump housing cover 1
9Bolt (water pump housing cover) 2
9Copper washer (coolant drain bolt) 3
9Coolant drain bolt 4
10 Nm (1.0 m•kg, 7.2 ft•lb)
10 Nm (1.0 m•kg, 7.2 ft•lb)
14 Nm (1.4 m•kg, 10 ft•lb)
1P8-9-30-4C 21/5/04 12:59 PM Page 12

4-65
CRANKCASE AND CRANKSHAFTENG
Extent of removal Order Part name Q’ty Remarks
CRANKCASE AND CRANKSHAFT
REMOVAL
Preparation for Engine Refer to “ENGINE REMOVAL”section.
removal Piston Refer to “
CYLINDER HEAD, CYLINDER
AND PISTON
” section.
Primary drive gear
Kick idle gearRefer to “
KICK AXLE, SHIFT SHAFT AND
Stopper leverPRIMARY DRIVE GEAR”section.
Rotor and stator Refer to “CDI MAGNETO” section.
1 Segment 1
2 Bolt [L=50 mm (1.97 in)] 7
3 Bolt [L=60 mm (2.36 in)] 1
4 Bolt [L=70 mm (2.76 in)] 3
5 Holder 2
6 Crankcase (right) 1 Use special tool.
7 Crankcase (left) 1 Refer to “REMOVAL POINTS”.
8 Crankshaft 1 Use special tool.
Refer to “REMOVAL POINTS”.
9 Oil seal 2
10 Bearing 2 Refer to “REMOVAL POINTS”.




EC4N0000
CRANKCASE AND CRANKSHAFT
12
3
Extent of removal:1Crankcase separation2Crankshaft removal
3Crankshaft bearing removal



10 Nm (1.0 m•kg, 7.2 ft•lb)30 Nm (3.0 m•kg, 22 ft•lb)
14 Nm (1.4 m•kg, 10 ft•lb)
10 Nm (1.0 m•kg, 7.2 ft•lb)
1P8-9-30-4C 21/5/04 1:00 PM Page 32