Pro Action Reverse Installation

(All Except RX1)

NOTE: This kit must be installed by an authorized Yamaha dealer or qualified mechanic to ensure proper function and reliability. Refer to the Service Manual for torque specifications and procedures outlined in this manual.
 

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Preparation for Installation
 1. Lock parking lever.

2. Drain gear oil. Roll vehicle onto the left side. Loosen drain bolt CD. Roll vehicle back upright.

Place a drain pan beneath the drain bolt. Remove the drain bolt and drain oil. After draining oil, replace the drain bolt.
Preparation of Subassembly Parts

1 . Assemble Shift Rod Assembly
Universal Joint (right-handed screw) (1), Nut (right-hand thread (2),  Shift Rod (3), Nut (left-handed thread) (4) Joint 2 (left-handed thread) (5).
 



2. Assemble Joint Rod Assembly
Joint 2 (1), Nut (Right-hand thread) (2), Joint Rod (3), Nut (Left-hand thread) (4), Joint 1 (5)

 CAUTION
Be sure the rotating direction of threads are cor- rect when assembling the shift rod and joint rod assemblies.


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3. Assemble the chain housing cover (1) and lever (2) with the following parts:
 Bolt (3) Torque: 10Nm (1.0m-kg, 7.2 ft-Ib), Collar, Plain Washer(4)

 

 

 

 

 

4. Install the joint rod assembly to the chain housing cover with the following parts:
 Flange U-Nut (1), Plain Washer 2 (2), Pin (3), Clip (4)

 NOTE: The Ball Joint (3) and Clip (4) must be installed onto the reverse fork lever before the cover is installed onto the chain case.

5. Adjust the shaft length of the joint rod assembly. . Tighten or loosen joint rod to achieve specified
length.
Standard: a = 140mm
               b = 70mm

Removal of Parts

1. Remove muffler.

NOTE: If the vehicle has an electric starter, remove the battery bracket and the related parts to gain access to the chain case cover.

2. Remove the chain housing cover. Remove clamp after taking off bolt (1) and then move the radiator hose to allow access. Remove the three bolts (2) and bolt (3).

3. Loosen the drive chain. Loosen Tensioner Adjustment Bolt CD until
inside threads do not protrude housing.



Remove chain tensioner arm.

 

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4. Remove driven sprocket.

Remove Bolt (1) and sprocket along with the
 collar.

5. Parts no longer used:

Housing Cover (1), Collar (2), Driven Sprocket (3),  Washer (4), Flange Bolt (5)

 PZ500:
  Drive Gear
  Drive Gear Collar
  Chain

Reverse Idler Gear Assembly

1. Assemble the following parts:
 Reverse Gear Shaft (1), Plate (1) Bolt (M6 x 15) (3) x 2
 Torque: 10Nm (1.0m-kg, 7.2 ft-Ib)

NOTE: On the PZ500 (8DJ Kit), remove the drive sprocket, collar and chain. Replace these parts with the parts contained in the kit.
NOTE: Place the shaft groove into the cutout on the plate.

2. Install the following parts on the reverse gear shaft:
 Plain Washer (2), Drive Sprocket 2 Subassembly (1)

Apply oil on the arrow shown below

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CAUTION
 Be sure that Drive Sprocket (2) and Reverse
 Gear (1) are assembled in the correct direction.

3. Install the following parts:

Collar (3), Driven Sprocket 1(1), Plain Washer (2)


CAUTION
Make sure the Collar (3) and Driven Sprocket (1) are placed on the correct side.

4. Install the following parts:
 Reverse Gear Subassembly (1), Journal (2)


CAUTION
When installing the Reverse Gear Subassembly (1), its slots must face out.


5. Install the following parts:
 Compression Spring (1), Collar (2),  Washer (3), Flange Bolt (4)
 

Torque: 48Nm (4.8m-kg, 45 ft-Ib)

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6. Install the following parts:
 Compression Spring (1), Reverse Gear 1, Subassembly (2), Plain Washer (3)

CAUTION

Drive Sprocket dogs must be engaged with the Reverse Gear dogs.

7. Install the following parts: Chain Tensioner Arm (1)

8. Adjust the chain tension.

 Adjustment Steps
 Loosen Locknut (1), Turn the Adjuster in until it stops Tighten Locknut (1)

 9. Make sure the two points on the Shift Fork 1 are aligned on the Driven Gear grooves.

10. Install the following parts:
Chain Housing Cover, Flange Bolt (1) x 3, Flange Bolt (2), Torque all bolts to 10Nm (1.0m-kg, 7.2 ft-Ib)

CAUTION
 Make sure the Chain Case Gasket is installed correctly to ensure proper sealing

11. Install the following parts to fix the reverse gear. . Flange Bolt (M6x16) (1)

Torque: 10Nm (1.0m-kg, 7.2 ft-Ib)


Washer (rubber coated) (2)

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12. Install the following parts to secure the radiator hose.
Radiator Hose Clamp (1), Flange Bolt (2)

Torque: 10Nm (1.0m-kg, 7.2 ft-Ib)

Installation of Shift Lever Assembly

 13. Install the Shift Lever Assembly with two flange bolts (M6x25) (1) and a flange bolt (M6x40) (2). Torque: 10Nm (1.0m-kg, 7.2 ft-Ib)
 

Change the Shift Lever to the forward (FWD) position.

14. Install the Shift Rod Subassembly onto the Shift Lever Assembly using a 6mm Flange Locknut. Adjust the length of rod (a) and secure the other end.
 

Flange U Nut (M6) (1), Torque: 10Nm (1.0m-kg, 7.2 ft-Ib) . Plain Washer (017) (2)

Adjusting Steps
1- Change the Shift Lever to the forward (FWD) position.
2- Loosen Locknut. (2)
3- Turn the Shift Rod (1) inward until the free play reaches Omm (a) must be shortened), then turn the Shift Rod outward 1/4 turn.
4- Tighten Locknut.

Filling Oil

1. Fill gear oil.
Oil Type: Yamaha Gear Oil Oil Capacity: 250cc

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Check Oil Level

1. Place the vehicle on level ground.

2. Check the oil level

 Check Steps
. Remove level Gauge CD to clean the gauge point.

 NOTE: Clean metallic particles off of the magnet on the level gauge end.


Install level Gauge (1)
After removing the level Gauge, make sure the oil level is between the upper and lower levels.

(a) Upper level
(b) lower level
 

If below the lower level, add oil.
 

Install the level Gauge and position the Hook Ring (2), of the level Gauge, on the Projecting Part (3) of the gear case.

Installation of Back-up Buzzer

 1. Install Back-up Buzzer.

Back-up Buzzer (1) , Bolt (M5 x 15), Flange Nut

NOTE: To ease the installation of the buzzer, the screws indicated in the illustration may be removed to gain access.

Note:

The Beeper harness cables are tucked under the cowling on the right side along with the beeper plug from the harness.

Click to Enlarge Hood Notch Info

 

 

 

Click to Enlarge Parts List

 

 

 

Totallyamaha is not responsible for any damages that these modifications may cause to your vehicle; any modifications are your responsibility if you choose to do so. We are providing information ONLY. Some of these modifications may VOID your warranty and that is your responsibility to look into. The Totallyamaha users have passed along most of the information found on this site. If you have any questions or concerns about anything on this site talk to your dealer before using any of the information. Totallyamaha will not be liable for any damages or personal injury from any modification performed from this site.