2006 YAMAHA YZ250LC transmission oil

4-44
KICK AXLE, SHIFT SHAFT AND PRIMARY DRIVE GEARENG
3. Install:
9Shift lever assembly 1
9Shift guide 2
NOTE:
9The shift lever assembly is installed at the
same time as the shift guide.
9Apply the transmission oil on the bolt (segment)
shaft.
2. Install:
9Shift lever assembly 1
To shift guide 2.
EC4C5202
Shift guide and shift lever assembly
1. Install:
9Spring 1
9Pawl pin 2
9Pawl 3
To shift lever 4.
EC4C5000
ASSEMBLY AND INSTALLATION
EC4C5130
Stopper lever
1. Install:
9Tension spring 1
9Holder 2
9Bolt (holder) 3
9Plain washer 4
9Stopper lever 5
9Bolt (stopper lever) 6
NOTE:
Align the stopper lever roller with the slot on seg-
ment.
10 Nm (1.0 m•kg, 7.2 ft•lb)
10 Nm (1.0 m•kg, 7.2 ft•lb)
1P8-9-31-4B 4/29/05 3:07 PM Page 34

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)
1P8-9-31-4B 4/29/05 3:08 PM 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.
1P8-9-31-4B 4/29/05 3:08 PM 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.
1P8-9-31-4C 5/12/05 1:20 PM Page 4

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.
1P8-9-31-4C 5/12/05 1:20 PM Page 8

Extent of removal Order Part name Q’ty Remarks
ENGINE REMOVAL
Preparation for
Hold the machine by placing the
removalsuitable stand under the engine.
Drain the transmission oil. Refer to “TRANSMISSION OIL
REPLACEMENT” section in the
CHAPTER 3.
Seat and fuel tankRefer to “SEAT, FUEL TANK AND
SIDE COVERS” section.
CarburetorRefer to “CARBURETOR AND REED
VALVE” section.
Exhaust pipe and silencer Refer to “EXHAUST PIPE AND
Exhaust pipe stay (rear) SILENCER” section.
Clutch cable Disconnect at engine side.
Radiator Refer to “RADIATOR” section.
Spark plug
Disconnect the CDI magneto lead.
4-60
ENGINE REMOVALENG
EC4M0000
ENGINE REMOVAL
w
Support the machine securely so there is no dan-
ger of it falling over.



26 Nm (2.6 m•kg, 19 ft•lb)
64 Nm (6.4 m•kg, 46 ft•lb)
75 Nm (7.5 m•kg, 54 ft•lb)
5 Nm (0.5 m•kg, 3.6 ft•lb)
34 Nm (3.4 m•kg, 24 ft•lb)
64 Nm (6.4 m•kg, 46 ft•lb)
85 Nm (8.5 m•kg, 61 ft•lb)
åExcept for USA and CDN
4 Nm (0.4 m•kg, 2.9 ft•lb)
1P8-9-31-4C 5/12/05 1:20 PM Page 22

4-70
CRANKCASE AND CRANKSHAFTENG
3. Install:
9O-ring 1
To crankcase (right) 2.
5. Install:
9Dowel pin 1
9Crankcase (right) 2
To crankcase (left) 3.
NOTE:
9Fit the crankcase (right) onto the crankcase
(left). Tap lightly on the case with soft hammer.
9When installing the crankcase, the connecting
rod should be positioned at TDC (top dead
center).
cC
In order to prevent the oil seal lipa a
from
being turned up or damaged, wrap a vinyl
tape or the likeb b
around the right end of
the crankshaft and apply the lithium soap
base grease over the tape.
NOTE:
Clean the contacting surface of crankcase (left
and right) before applying the sealant.
4. Apply:
9Sealant
On the crankcase (right) 1.
Quick gasket®:
ACC-QUICK-GS-KT
Yamaha bond No. 1215:
90890-85505
2. Check:
9Shifter operation
9Transmission operation
Unsmooth operation
Repair.
1P8-9-31-4C 5/12/05 1:21 PM Page 42

6. Install:
9Holder (except for USA and CDN) 1
9Bolt [holder (except for USA and CDN)] 2
9Bolt (crankcase)
NOTE:
Tighten the crankcase tightening bolts in stage,
using a crisscross pattern.
4-71
CRANKCASE AND CRANKSHAFTENG
8. Tighten:
9Segment 1
9Bolt (segment) 2
NOTE:
9When installing the segment onto the shift cam
3, align the punch mark awith the dowel pin
b.
9Turn the segment clockwise until it stops and
tighten the bolt.
cC
If the segment gets an impact, it may be
damaged. Take care not to give an impact
to the segment when tightening the bolt.
30 Nm (3.0 m•kg, 22 ft•lb)
7. Install:
9Tension spring 1
9Holder 2
9Bolt (holder) 3
NOTE:
Install the holder so that it contacts the projec-
tion aon the crankcase (right).
10 Nm (1.0 m•kg, 7.2 ft•lb)
9. Remove:
9Sealant
Forced out on the cylinder mating surface.
10. Apply:
9Engine oil
To the crank pin, bearing, oil delivery hole
and connecting rod big end washer.
11. Check:
9Crankshaft and transmission operation
Unsmooth operation
Repair.
14 Nm (1.4 m•kg, 10 ft•lb)
14 Nm (1.4 m•kg, 10 ft•lb)
1P8-9-31-4C 5/12/05 1:21 PM Page 44