Yamaha YZ450F(Y Owner's Manual Page 130

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REMOVING THE TRANSMISSION
1. Remove:
• Main axle "1"
• Drive axle "2"
• Shift cam
• Shift fork 3
• Shift fork 2
• Shift fork 1
• Remove assembly with the collar
"3" installed to the crankcase.
• Remove assembly carefully. Note
the position of each part. Pay partic-
ular attention to the location and di-
rection of shift forks.
• Remove the main axle, drive axle,
shift cam and shift fork all together
by tapping lightly on the transmis-
sion drive axle with a soft hammer.
CHECKING THE GEARS
1. Inspect:
• Matching dog "a"
• Gear teeth "b"
• Shift fork groove "c"
Wear/damage → Replace.
2. Inspect:
• O-ring "1"
Damage → Replace.
3. Check:
• Gears movement
Unsmooth movement→Repair or
replace.
CHECKING THE BEARING
1. Inspect:
• Bearing "1"
Rotate inner race with a finger.
Rough spot/seizure → Replace.
TRANSMISSION, SHIFT CAM AND SHIFT FORK
CHECKING THE SHIFT FORK,
SHIFT CAM AND SEGMENT
1. Inspect:
• Shift fork "1"
Wear/damage/scratches → Re-
place.
2. Inspect:
• Shift cam "1"
• Segment "2"
Wear/damage → Replace.
3. Check:
• Shift fork movement
Unsmooth operation → Replace
shift fork.
For a malfunctioning shift fork, re-
place not only the shift fork itself but
the two gears each adjacent to the
shift fork.
INSTALLING THE TRANSMISSION
1. Install:
• 5th pinion gear (21T) "1"
• 3rd pinion gear (18T) "2"
• Collar "3"
• 4th pinion gear (22T) "4"
• 2nd pinion gear (15T) "5"
To main axle "6".
4-60
Apply the molybdenum disulfide oil
on the inner and end surface of the
idler gear and on the inner surface of
the sliding gear, then install.
2. Install:
• Collar "1"
• 2nd wheel gear (23T) "2"
• 4th wheel gear (24T) "3"
• 3rd wheel gear (23T) "4"
• 5th wheel gear (20T) "5"
• Collar "6"
• 1st wheel gear (27T) "7"
• O-ring "8"
To drive axle "9".
• Apply the molybdenum disulfide oil
on the inner and end surface of the
idler gear and on the inner surface
of the sliding gear, then install.
• Apply the lithium soap base grease
on the O-ring.
3. Install:
• Washer "1"
• Circlip "2"

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  • nick Jan 26, 2016 10:47:
    The download is jacked up, so it's only really viewable on the site, but can't really complain since it's free.