TRANSMISSION
5-67
3. Check:
l
Transmission gears
Blue discoloration/pitting/wear
→
Replace
the defective gear(s).
l
Transmission gear dogs
Cracks/damage/rounded edges
→
Replace
the defective gear(s).
4. Check:
l
Transmission gear engagement
(each pinion gear to its respective wheel
gear)
Incorrect
→
Reassemble the transmission
axle assemblies.
5. Check:
l
Transmission gear movement
Rough movement
→
Replace the defective
part(s).
CHECKING THE CLUTCH PUSH RODS
1. Check:
l
Long clutch push rod
Cracks/damage/wear
→
Replace the long
clutch push rod.
2. Measure:
l
Push rod bending limit
Out of specification
→
Replace the long
clutch push rod.
ASSEMBLING THE MAIN AXLE AND DRIVE
AXLE
1. Install:
l
Toothed washer “1”
l
Circlip “2”
NOTE:
Be sure to install the circlip so that its sharp
edge “a” is facing away from the toothed wash-
er and gear.
l
Be sure the circlip ends “b” are positioned at
the axle spline groove“c”.
2. Install:
l
2nd pinion gear “1”
NOTE:
Press the 2nd pinion gear into the main axle “2”,
as shown in the illustration.
INSTALLING THE SHIFT FORKS AND SHIFT
DRUM ASSEMBLY
1. Install:
l
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”
Push rod bending limit
0.500 mm
Installed depth “a”
106.85–107.05 mm
New
a
1
2
c
b
New
1
2
a
l
5-68
TRANSMISSION
NOTE:
The embossed marks on the shift forks should
face towards the right side of the engine and be
in the following sequence:“R”, “C”, “L”.
2. Check:
l
Transmission
Rough movement
→
Repair.
NOTE:
l
Apply engine oil to each gear and bearing thor-
oughly.
l
Before assembling the crankcase, make sure
that the transmission is in neutral and that the
gears turn freely.
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 ...