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PANTHERA MOTORSPORTS
YZ250-YZ250X Electric starter - Installation guide
List of Panthera parts you need
1- Panthera starter electric motor
2- Lighting Stator*
3- Panthera flywheel*
4- High strength 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.
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Summary of Contents for Panthera Motosports YZ250
- Page 1 PANTHERA MOTORSPORTS YZ250-YZ250X Electric starter - Installation guide List of Panthera parts you need 1- Panthera starter electric motor 2- Lighting Stator* 3- Panthera flywheel* 4- High strength flywheel adapter 5- Main starter gear/clutch 6- Needle bearing 7- Bolting nut and bearing holder...
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Page 2: Security Concerns
PANTHERA MOTORSPORTS YZ250-YZ250X Electric starter - Installation guide List of tools you need 1- 3/8 drive Socket ranch 2- Socket ranch extension 3- 10mm socket 4- Phillips drive bit 5- Yamaha M27x1 flywheel puller 6- 6mm allen drive bit 7- 5mm allen drive bit... - Page 3 PANTHERA MOTORSPORTS YZ250-YZ250X Electric starter - Installation guide Original parts disassembly In order to make the wiring installation, the motorcycle seat and fuel tank have to be removed. Seat removal With a 10mm socket, remove the two seat bolts on each side and remove the seat.
- Page 4 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)
- Page 5 PANTHERA MOTORSPORTS YZ250-YZ250X Electric starter - Installation guide Run the wiring loom between the airbox and under the chassis shock tower. The plastic of the airbox if often very sharp, it is suggested to file the sharp edge of the plastic to ensure wires don’t get cut over time.
- Page 6 PANTHERA MOTORSPORTS YZ250-YZ250X Electric starter - Installation guide Connect the stator 6 pins connector to the bike harness. Connect the charging coil 2 pins connector to the bike harness Flywheel and main gear installation (for starter kit without charging system) To run the starter assembly while keeping the original flywheel and stator, it is required to change the flywheel heart for the new supplied heart with a starter coupling.
- Page 7 PANTHERA MOTORSPORTS YZ250-YZ250X Electric starter - Installation guide Using the gear holding tool supplied and a 1/2in torque wrench, torque the bolting unit to 40 ft-lb. Make sure the main gear is still rotation freely clockwise and locking counterclockwise. To ensure proper installation, measure the distance of the ring gear face to the gasket surface on the engine.
- Page 8 PANTHERA MOTORSPORTS YZ250-YZ250X Electric starter - Installation guide Place the starter flywheel flange 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.
- Page 9 PANTHERA MOTORSPORTS YZ250-YZ250X Electric starter - Installation guide Make sure the main gear is still rotation freely clockwise and locking counterclockwise. To ensure proper installation, measure the distance of the ring gear face to the gasket surface on the engine. Some cranks can be out of specifications or have been re-machined due to previous damages to crankshaft taper.
- Page 10 PANTHERA MOTORSPORTS YZ250-YZ250X Electric starter - Installation guide If you are running the starter without charging system, you will need to put the supplied steel shim with two gaskets. To make the installation easier, you can silicone the two gaskets on each side of the steel shim so they all stay together.
- Page 11 PANTHERA MOTORSPORTS YZ250-YZ250X Electric starter - Installation guide Place gear cap and its gasket back on and bolt it on with the 4 button heads. Use blue Loctite and torque to 90 in-lb. The housing is equipped with a pressure vent at the back made to run a hose to a high point on the motorcycle, at least one feet higher than the housing.
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Page 12: Maintenance
PANTHERA MOTORSPORTS YZ250-YZ250X Electric starter - Installation guide Maintenance It is recommended to flush the oil after the first 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. - Page 13 PANTHERA MOTORSPORTS YZ250-YZ250X Electric starter - Installation guide Annexe 1 YZ250 Wiring diagram...
- Page 14 PANTHERA MOTORSPORTS 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...
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Page 15: Returns And Exchanges
PANTHERA MOTORSPORTS YZ250-YZ250X Electric starter - Installation guide Returns and Exchanges General: All returns must be postmarked no later than 10 days from the original customer shipment date. Returns and exchanges must be in new condition and must include all instructions and original packing material. -
Page 16: Warranty Items
PANTHERA MOTORSPORTS YZ250-YZ250X Electric starter - Installation guide Warranty Items: All merchandise manufactured by Panthera Motorsports has a warranty against manufacturing defects for a period of one (1) year from the date of original shipping. Warranty is limited to the repair or replacement of defective products.