Checking The Clutch Push Rods; Assembling The Main Axle And Drive Axle; Installing The Shift Forks And Shift Drum Assembly - Yamaha YZF-R15 Service Manual

3. Check:
Transmission gears
l
Blue discoloration/pitting/wear → Replace
the defective gear(s).
Transmission gear dogs
l
Cracks/damage/rounded edges → Replace
the defective gear(s).
4. Check:
Transmission gear engagement
l
(each pinion gear to its respective wheel
gear)
Incorrect → Reassemble the transmission
axle assemblies.
5. Check:
Transmission gear movement
l
Rough movement → Replace the defective
part(s).

CHECKING THE CLUTCH PUSH RODS

1. Check:
Long clutch push rod
l
Cracks/damage/wear → Replace the long
clutch push rod.
2. Measure:
Push rod bending limit
l
Out of specification → Replace the long
clutch push rod.
Push rod bending limit
0.500 mm
ASSEMBLING THE MAIN AXLE AND DRIVE
AXLE
1. Install:
Toothed washer "1"
l
Circlip "2" New
l
NOTE:
Be sure to install the circlip so that its sharp
l
edge "a" is facing away from the toothed wash-
er and gear.
Be sure the circlip ends "b" are positioned at
l
the axle spline groove"c".
New 2
1
a
2. Install:
2nd pinion gear "1"
l
NOTE:
Press the 2nd pinion gear into the main axle "2",
as shown in the illustration.
Installed depth "a"
106.85–107.05 mm
a
1
INSTALLING THE SHIFT FORKS AND SHIFT
DRUM ASSEMBLY
1. Install:
Shift fork-L "1"
l
Shift fork-C "2"
l
Shift fork-R "3"
l
Shift drum assembly "4"
l
Springs
l
Shift fork guide bar "5"
l
5-67
TRANSMISSION
b
c
2