YZ490 Kick Start Return Spring Replacement

Question:

Can you tell me how to replace a YZ490 kick start return spring? Thanks 4 any help. {Rob, NJ 1982 Yamaha YZ490 }

Answer:

To replace the YZ490 kick start return spring, you will need to remove the right side engine cover so make sure you have a few rags or a roll of paper towels and a drain pan handy. You may want to order the gasket {Yamaha Part Number 3R4-154-62-00-00} when you place the order for the spring. In case you rip yours when removing the cover. All of the numbers in parentheses { } refer to the parts diagram below.


1982 Yamaha YZ490 Kick Start Spring Diagram



Start by removing the nut {#18} on the kick start shaft. Remove the kick starter. Yamaha calls it a kick crank. Next remove the drain bolt under the engine and catch the engine oil in a drain pan. This would be a good time to do an oil change.

Next, remove the right side engine cover, taking care not to damage the gasket. Slightly loosen the engine cover and run a razor blade under the gasket. When you are ready to pull the cover off, push in on the kick start shaft {Kick Axle # 1} with your thumbs, so that the cover slides over the shaft. You want the shaft to remain in the engine when the cover comes off. If the oil seal {#10} does not stay in the cover, remove it now.

When looking at the kicker shaft, you will see that there is a sleeve {#6} inside the spring {#5}. Slide out the sleeve, noting the placement of the notches. Remove the spring {#5} and replace. Reinstall the sleeve with the notches in the same orientation as they were when you removed it.

Reinstall the oil seal, engine cover, kick starter & nut. Replace the oil.

I advise you to do it this way to save yourself a lot of time and hassle. By maintaining pressure on the kick start shaft while you remove the engine cover, you avoid having to realign the kicker gears in the engine to reinsert the shaft. Which is no easy task in the YZ490.


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