Yamaha XT250X - Installing the Shift Forks and Shift Drum Assembly

TRANSMISSION
5-64
3. Check:
●
Transmission gears
Blue discoloration/pitting/wear → Replace
the defective gear(s).
● Transmission gear dogs
Cracks/damage/wear → Replace the defec-
tive gear(s).
4. Check:
● Transmission gear engagement
(each pinion gear to its respective wheel
gear)
Incorrect → Reassemble the transmission
axle assemblies.
NOTE:
When reassembling the main axle “1”, press the
2nd pinion gear “2” onto it as shown.
5. Check:
● Transmission gear movement
Rough movement → Replace the defective
part(s).
6. Check:
●
Circlips
Bends/damage/looseness → Replace.
EAS26320
INSTALLING THE SHIFT FORKS AND SHIFT
DRUM ASSEMBLY
1. Install:
● Shift fork-L “1”
● Shift fork-C
● Shift fork-R “2”
●
Shift drum assembly “3”
● Shift fork guide bars “4”
NOTE:
The embossed marks (“R”/“C”/“L”) on the shift
forks should face towards the right side of the
engine.
2. Check:
●
Transmission
Rough movement → Repair.
NOTE:
Oil each gear, shaft, and bearing thoroughly.
a. 102.2–102.4 mm