Yamaha yz250 2015, Owner'S Manual

Page: 91 / 174

4-27
KICK SHAFT AND SHIFT SHAFT
REMOVING THE PRIMARY DRIVE
GEAR
1. Loosen:
• Bolt (primary drive gear) "1"
Place an aluminum plate "a" between
the teeth of the primary drive gear "2"
and driven gear "3".
REMOVING THE KICK SHAFT
ASSEMBLY
1. Remove:
• Kick shaft assembly "1"
Unhook the torsion spring "2" from
the hole "a" in the crankcase.
REMOVING THE SHIFT GUIDE
AND SHIFT LEVER ASSEMBLY
1. Remove:
• Bolt (shift guide)
• Shift guide "1"
• Shift lever assembly "2"
The shift lever assembly is disassem-
bled at the same time as the shift
guide.
REMOVING THE SEGMENT
1. Remove:
• Bolt (segment) "1"
• Segment "2"
Turn the segment counterclockwise
until it stops and loosen the bolt.
If the segment gets an impact, the
stopper lever may be damaged.
Take care not to give an impact to
it when removing the bolt.
CHECKING THE KICK SHAFT AND
RATCHET WHEEL
1. Check:
• Ratchet wheel "1" smooth move-
ment
Unsmooth movement
→
Replace.
• Kick shaft "2"
Wear/damage
→
Replace.
• Spring "3"
Broken → Replace.
CHECKING THE KICK GEAR, KICK
IDLE GEAR AND RATCHET
WHEEL
1. Inspect:
• Kick gear "1"
• Kick idle gear "2"
• Ratchet wheel "3"
• Gear teeth "a"
• Ratchet teeth "b"
Wear/damage
→
Replace.
CHECKING THE SHIFT SHAFT
1. Inspect:
• Shift shaft "1"
Bend/damage
→
Replace.
• Spring "2"
Broken
→
Replace.
CHECKING THE SHIFT GUIDE AND
SHIFT LEVER ASSEMBLY
1. Inspect:
• Shift guide "1"
• Shift lever "2"
• Pawl "3"
• Pawl pin "4"
• Spring "5"
Wear/damage
→
Replace.
CHECKING THE STOPPER LEVER
1. Inspect:
• Stopper lever "1"
Wear/damage
→
Replace.
• Bearing "2"
Rotate outer race with a finger.
Rough spot/Seizure
→
Replace
the stopper lever.
• Torsion spring "3"
Broken
→
Replace.
CHECKING THE PRIMARY DRIVE
GEAR AND PRIMARY DRIVEN
GEAR
1. Inspect:
• Primary drive gear "1"
• Primary driven gear "2"
Wear/Damage
→
Replace.