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Panthera Motosports YZ250, Installation Manual

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Panthera Motosports YZ250 Installation Manual Download Page 4

PANTHERA MOTORSPORTS 

YZ250-YZ250X Electric starter - Installation guide 

 

 

Flywheel and stator removal (for starter kit with charging system) 

 

With a philips drive bit, remove the 5 flywheel cover bolts and cover.  

With a M27x1 flywheel puller, remove the original flywheel. 

Unplug the stator connector located between the two radiators. 

With a philips drive bit, remove the 3 stator bolts and the stator. 

Clean the case internal so that no dirt remains. 

Panthera system installation 

Battery box and wiring installation 

The battery box for the YZ250 2022 is a drop in configuration. It is made to be held in place by the seat. 
It can then be lift off for air filter change. (see example below) 

     

 

Summary of Contents for YZ250

Page 1: ...th flywheel adapter 5 Main starter gear clutch 6 Needle bearing 7 Bolting nut and bearing holder 8 Panthera starter cover and cap 9 Sealed ball bearing 10 Crown starter gear 11 Intermediate torque limiter gear 12 Starter relay 13 Current rectifier 14 Battery box 15 Wiring harness 16 Starter button 17 Carbon fiber shield Optional components only if these options were selected in the kit ...

Page 2: ... bit 7 5mm allen drive bit 8 4mm allen drive bit 9 60 150 in lb torque wrench 10 drive torque wrench Security concerns Engine assembly must always be accomplished by a qualified mechanic Use the proper tools for every operation and always wear the proper personal protective equipment glass gloves etc The parts sold by Panthera Motorsports are often machined parts and are at risk of having sharp ed...

Page 3: ... the tank With an extension and a 10mm socket remove the two bolts holding the tank to the chassis as well as the two bolts between the tank side covers and the radiator guards Making sure the fuel valve is closed slide off the collar and remove the fuel line using a rag to collect the fuel drop Flywheel removal for starter kit without charging system With a Philips drive bit remove the 5 flywheel...

Page 4: ...move the original flywheel Unplug the stator connector located between the two radiators With a philips drive bit remove the 3 stator bolts and the stator Clean the case internal so that no dirt remains Panthera system installation Battery box and wiring installation The battery box for the YZ250 2022 is a drop in configuration It is made to be held in place by the seat It can then be lift off for...

Page 5: ...nd red are to follow down the clutch cable towards the starter cover Install the starter button to the handlebars with the supplied camp and connect to the harness Panthera stator installation for starter kit with charging system Place the new stator inside the casing and ensure the that rubber boot is properly sliding in its location Proper seat of the rubber is important as the starter housing w...

Page 6: ... stator it is required to change the flywheel heart for the new supplied heart with a starter coupling Follow the specific flywheel heart replacement instruction supplied with your new flywheel heart Clean the inside of the flywheel of any chip or dirt and prepare for installation Slide the flywheel on the crankshaft and assure the keyway aligns with the woodruff key on the crank Place the main ri...

Page 7: ... proper distance is could damage the stator or prevent the starter gears from spinning Push the gear toward the engine as mush as it can and measure distance to engine gasket surface The tolerance for the gear distance is 19 0 to 20 8mm Flywheel and main gear installation for starter kit with charging system Slide the Panthera flywheel on the crankshaft and assure the keyway aligns with the woodru...

Page 8: ...nge on the flywheel by aligning the six locator pins Place the main ring gear on the flange by rotating it clockwise while you push it on Put the needle bearing in the middle and insert the bolting unit Using the gear holding tool supplied and a 1 2in torque wrench torque the bolting unit to 40 ft lb ...

Page 9: ...amages to crankshaft taper If the flywheel doesn t sit at proper distance is could damage the stator or prevent the starter gears from spinning Push the gear toward the engine as mush as it can and measure distance to engine gasket surface The tolerance for the gear distance is 17 0 to 18 5 Make sure that the clutch actuator arm has clearance from the flywheel trigger bumg if too close slightly be...

Page 10: ...starter gears Install the housing on the engine with the proper gasket and ensure the housing central bearing is sliding on the flywheel bolting unit Hold the cover in place and bolt it with the 5 allen cap screw With a 5mm torque the cover housing to 90 in lb Make sure the main gear is still spinning freely clockwise Pour 300ml of ATF type F oil inside the starter housing Place the two small gear...

Page 11: ...ry and the 4 cells box for the Antigravity SC 1 Connect the harness to the battery always connect the positive red first Once wires placed properly tight the two nuts on the relay with at 10mm socket Tank and seat re install Re install the fuel tank on and make sure none of the connectors are interfering Bolt the tank back in place Chassis bolt torque is 86 in lb and guard bolts torque is 51 in lb...

Page 12: ... ride to eliminate particles generated by the gears first meshing and break in Taking cover off to remove all particles is recommended versus only using the drain plug On a normal basis change the oil at the same time as transmission oil Flywheel puller The suppler gear holder to torque the flywheel also acts like a flywheel puller ...

Page 13: ...PANTHERA MOTORSPORTS YZ250 YZ250X Electric starter Installation guide Annexe 1 YZ250 Wiring diagram ...

Page 14: ...PORTS YZ250 YZ250X Electric starter Installation guide Annexe 2 Electric starter system wiring diagram Power with delay yellow red wire is a 12V current source that only charges few seconds after the engine is started ...

Page 15: ...t Item If you received an incorrect item we must be notified within 10 days of receipt of the shipment so that no extra charges will be incurred We will replace incorrect items and pay the additional shipping charge No returns of items will be accepted beyond 21 days of the original shipment date Return Shipping Instructions Return via prepaid mail only Insure shipment for full value of purchase U...

Page 16: ...ve is not valued at the full purchase price A depreciated value will be estimated for used product Warranty excludes product that has been modified or where the product was improperly installed abnormally used or misused This limited warranty is in lieu of all other guarantees or warranties implied or expressed This includes without limitation any warranties or merchantability and fitment for a pa...

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