TRANSMISSION
5-65
Disassembling the drive axle
Order
Job/Parts to remove
Qty
Remarks
1
Washer
1
2
2nd wheel gear
1
3
6th wheel gear
1
4
Washer
1
5
1st wheel gear
1
6
Spacer
1
7
5th wheel gear
1
8
Circlip
1
9
Toothed washer
1
10
4th wheel gear
1
11
3rd wheel gear
1
12
Drive axle
1
For assembly, reverse the disassembly pro-
cedure.
5-66
TRANSMISSION
CHECKING THE SHIFT FORKS
The following procedure applies to all of the shift
forks.
1. Check:
l
Shift fork cam follower “1”
l
Shift fork pawl “2”
Bends/damage/scoring/wear
→
Replace the
shift fork.
2. Check:
l
Shift fork guide bar
Roll the shift fork guide bar on a flat surface.
Bends
→
Replace.
WARNING
Do not attempt to straighten a bent shift fork
guide bar.
3. Check:
l
Shift fork movement
(along the shift fork guide bar)
Rough movement
→
Replace the shift forks
and shift fork guide bar as a set.
CHECKING THE SHIFT DRUM ASSEMBLY
1. Check:
l
Shift drum groove
Damage/scratches/wear
→
Replace the shift
drum assembly.
l
Shift drum segment “1”
Damage/wear
→
Replace the shift drum as-
sembly.
l
Shift drum bearing “2”
Damage/pitting
→
Replace the shift drum as-
sembly.
CHECKING THE TRANSMISSION
1. Measure:
l
Main axle runout
(with a centering device and dial gauge “1”)
Out of specification
→
Replace the main axle.
2. Measure:
l
Drive axle runout
(with a centering device and dial gauge “1”)
Out of specification
→
Replace the drive axle.
Main axle runout limit
0.08 mm
Drive axle runout limit
0.08 mm
Summary of Contents for YZF-R15
Page 1: ...2008 SERVICE MANUAL YZF R15 20P F8197 E0 ...
Page 33: ...2 14 ELECTRICAL SPECIFICATIONS Coil resistance 54 0 66 0 Fuse 20 0A Ω Fuse ...
Page 46: ...2 27 LUBRICATION POINTS AND LUBRICANT TYPES LUBRICATION DIAGRAMS A 1 2 3 4 5 6 7 ...
Page 48: ...2 29 LUBRICATION POINTS AND LUBRICANT TYPES 1 2 3 4 ...
Page 49: ...2 30 LUBRICATION POINTS AND LUBRICANT TYPES 1 Camshaft 2 Crankshaft 3 Main axle 4 Drive axle ...
Page 50: ...2 31 COOLING SYSTEM DIAGRAMS COOLING SYSTEM DIAGRAMS 1 2 3 4 1 5 7 6 4 ...
Page 52: ...2 33 CABLE ROUTING CABLE ROUTING 1 5 2 3 6 4 8 7 ...
Page 54: ...2 35 CABLE ROUTING A A B B C C A A C C B B A B C 1 2 3 4 5 4 5 6 6 7 8 9 10 11 10 11 12 12 ...
Page 56: ...2 37 CABLE ROUTING 1 2 5 4 3 ...
Page 60: ...2 41 CABLE ROUTING A A B C D E 1 2 3 4 5 6 7 8 9 10 A ...
Page 121: ...4 24 FRONT BRAKE Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 18 ...
Page 249: ...7 8 THROTTLE BODY ...
Page 250: ...7 9 AIR INDUCTION SYSTEM AIR INDUCTION SYSTEM 1 2 5 4 5 6 3 2 1 6 4 3 ...
Page 257: ......
Page 269: ...8 12 CHARGING SYSTEM 1 AC magneto 2 Rectifier regulator 3 Battery 42 Fuse ...
Page 271: ...8 14 CHARGING SYSTEM ...
Page 275: ...8 18 LIGHTING SYSTEM ...
Page 285: ...8 28 COOLING SYSTEM ...
Page 311: ...8 54 FUEL PUMP SYSTEM ...