transmission YAMAHA YZ250F 2009 User Guide

4-58
CRANKCASE AND CRANKSHAFT
5. Install:
• Dowel pin "1"
• O-ring "2"
• Right crankcase
To left crankcase.
• Apply the lithium soap base grease
on the O-ring.
• Fit the right crankcase onto the left
crankcase. Tap lightly on the case
with soft hammer.
• When installing the crankcase, the
connecting rod should be posi-
tioned at TDC (top dead center).
6. Tighten:
• Hose guide "1"
• Clutch cable holder "2"
• Bolt (crankcase) "3"
Tighten the crankcase tightening
bolts in stage, using a crisscross pat-
tern.
7. Install:
• Oil delivery pipe 2 "1"
• O-ring "2"
• Bolt (oil delivery pipe 2) "3"
Apply the lithium soap base grease
on the Orings.
8. Install:
• Timing chain "1"
• Timing chain guide (intake side)
"2"
• Bolt (timing chain guide) "3"
9. Remove:
•Sealant
Forced out on the cylinder mating
surface.
10. Apply:
• Engine oil
To the crank pin, bearing and oil
delivery hole.
11. Check:
• Crankshaft and transmission op-
eration.
Unsmooth operation→Repair. Bolt (crankcase):
12 Nm (1.2 m•kg, 8.7
ft•lb)
Bolt (oil delivery pipe 2):
10 Nm (1.0 m•kg, 7.2
ft•lb)
Bolt (timing chain guide):
10 Nm (1.0 m•kg, 7.2
ft•lb)

4-59
TRANSMISSION, SHIFT CAM AND SHIFT FORK
TRANSMISSION, SHIFT CAM AND SHIFT FORK
REMOVING THE TRANSMISSION, SHIFT CAM AND SHIFT FORK
Order Part name Q'ty Remarks
Engine Refer to "ENGINE REMOVAL" section.
Separate the crankcase.Refer to "CRANKCASE AND CRANK-
SHAFT" section.
1 Main axle 1 Refer to removal section.
2 Drive axle 1 Refer to removal section.
3 Shift cam 1 Refer to removal section.
4 Shift fork 3 1 Refer to removal section.
5 Shift fork 2 1 Refer to removal section.
6 Shift fork 1 1 Refer to removal section.
7Collar 1

4-60
TRANSMISSION, SHIFT CAM AND SHIFT FORK
REMOVING THE TRANSMISSION
1. Remove:
• Main axle "1"
•Drive axle "2"
•Shift cam
• Shift fork 3
• Shift fork 2
• Shift fork 1
• Remove assembly with the collar
"3" installed to the crankcase.
• Remove assembly carefully. Note
the position of each part. Pay partic-
ular attention to the location and di-
rection of shift forks.
• Remove the main axle, drive axle,
shift cam and shift fork all together
by tapping lightly on the transmis-
sion drive axle with a soft hammer.
CHECKING THE GEARS
1. Inspect:
• Matching dog "a"
• Gear teeth "b"
• Shift fork groove "c"
Wear/damage→Replace.
2. Inspect:
• O-ring "1"
Damage→Replace.
3. Check:
• Gears movement
Unsmooth movement→Repair or
replace.
CHECKING THE BEARING
1. Inspect:
• Bearing "1"
Rotate inner race with a finger.
Rough spot/seizure→Replace.CHECKING THE SHIFT FORK,
SHIFT CAM AND SEGMENT
1. Inspect:
• Shift fork "1"
Wear/damage/scratches→Re-
place.
2. Inspect:
• Shift cam "1"
• Segment "2"
Wear/damage→Replace.
3. Check:
• Shift fork movement
Unsmooth operation→Replace
shift fork.
For a malfunctioning shift fork, re-
place not only the shift fork itself but
the two gears each adjacent to the
shift fork.
INSTALLING THE TRANSMISSION
1. Install:
• 5th pinion gear (24T) "1"
• 3rd pinion gear (20T) "2"
•Collar "3"
• 4th pinion gear (22T) "4"
• 2nd pinion gear (16T) "5"
To main axle "6".
Apply the molybdenum disulfide oil
on the inner and end surface of the
idler gear and on the inner surface of
the sliding gear, then install.
2. Install:
• 2nd wheel gear (28T) "1"
• 4th wheel gear (27T) "2"
• 3rd wheel gear (29T) "3"
• 5th wheel gear (25T) "4"
• 1st wheel gear (30T) "5"
• O-ring "6"
To drive axle "7".
• Apply the molybdenum disulfide oil
on the inner and end surface of the
idler gear and on the inner surface
of the sliding gear, then install.
• Apply the lithium soap base grease
on the O-ring.
3. Install:
• Washer "1"
• Circlip "2"

4-61
TRANSMISSION, SHIFT CAM AND SHIFT FORK
• Be sure the circlip sharp-edged cor-
ner "a" is positioned opposite side
to the washer and gear "b".
• Install the circlip with its ends "c"
settled evenly on the spline crests.
4. Install:
•Collar "1"
• Apply the lithium soap base grease
on the oil seal lip.
• When installing the collar into the
crankcase, pay careful attention to
the crankcase oil seal lip.
5. Install:
• Shift fork 1 (L) "1"
• Shift fork 2 (C) "2"
• Shift fork 3 (R) "3"
•Shift cam "4"
To main axle and drive axle.
• Apply the molybdenum disulfide oil
on the shift fork grooves.
• Mesh the shift fork #1 (L) with the
4th wheel gear "5" and #3 (R) with
the 5th wheel gear "7" on the drive
axle.
• Mesh the shift fork #2 (C) with the
3rd pinion gear "6" on the main ax-
le.
6. Install:
• Transmission assembly "1"
To left crankcase "2".
Apply the engine oil on the bearings
and guide bars.
7. Check:
• Shifter operation
• Transmission operation
Unsmooth operation→Repair.