Yamaha Fz1n Service Manual
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CRANKSHAFT 5-83 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 2. Select: Crankshaft journal bearings (J1–J5) NOTE: The numbers “A” stamped into the crank-shaft web and the numbers “1” stamped into the lower crankcase are used to determine the replacement crankshaft journal bearing sizes. “J1–J5” refer to the bearings shown in the crankshaft illustration. If “J1–J5” are the same, use the same size for all of the bearings. If the size is the same for all “J 1 to J5” one digit for that size is indicated. (Crankcase side only) For example, if the crankcase “J 1” and crankshaft web “J 1” numbers are “6” and “2” respectively, then the bearing size for “J 1” is: ET2D1021 INSTALLING THE CRANKSHAFT 1. Install: Crankshaft journal upper bearings “1”(into the upper crankcase) 2. Lubricate: Crankshaft journal upper bearings(with the recommended lubricant) “J 1” (crankcase) – “J1” (crankshaft web) – 1 = 6 – 2 – 1 = 3 (brown) CRANKSHAFT JOURNAL BEARING COLOR CODE 0White 1Blue 2Black 3Brown 4Green Recommended lubricant Engine oil
CRANKSHAFT 5-84 NOTE: Align the projections “a” on the crankshaft journal upper bearings with the notches “b” in the upper crankcase. Be sure to install each crankshaft journal upper bearing in its original place. 3. Install: Crankshaft 4. Install: Crankcase (lower)Refer to CRANKCASE on page 5-66. 5. Install: Pin Pickup rotor “1” Drive sprocket “2” Drive sprocket bolt60 Nm (6.0 m·kg, 43 ft·lb)
TRANSMISSION 5-85 EAS26240 TRANSMISSION Removing the transmission, shift drum assembly, and shift forks Order Job/Parts to remove Q’ty RemarksCrankcase lower Separate. Refer to CRANKCASE on page 5- 66 . 1 Drive axle assembly 1 2 Circlip 1 3 Oil seal 1 4 Bearing 1 5 Washer 1 6 Shift fork guide bar retainer 2 7Spring 2 8 Shift fork guide bar 2 9 Shift fork “L” 1 10 Shift fork “R” 1 11 Shift drum assembly 1 12 Shift fork “C” 1 13 Main axle retainer 1
TRANSMISSION 5-86 14 Main axle assembly 1 15 Oil pipe 1 16 O-ring 2 17 Oil baffle plate 1For installation, reverse the removal procedure. Removing the transmission, shift drum assembly, and shift forks Order Job/Parts to remove Q’ty Remarks
TRANSMISSION 5-87 Disassembling the main axle assenbly Order Job/Parts to remove Q’ty Remarks1 2nd pinion gear 1 2 Toothed lock washer 1 3 Toothed lock washer retainer 1 4 6th pinion gear 1 5Collar 1 6 Washer 1 7 Circlip 1 8 3rd pinion gear 1 9 Circlip 1 10 Washer 1 11 5th pinion gear 1 12 Collar 1 13 Main axle 1 14 Bearing housing 1 15 Bearing 1 For assembly, reverse the disassem- bly procedure.
TRANSMISSION 5-88 Disassembling the drive axle assenbly Order Job/Parts to remove Q’ty Remarks1 Washer 1 2 1st wheel gear 1 3Collar 1 4 5th wheel gear 1 5 Circlip 1 6 Washer 1 7 3rd wheel gear 1 8Collar 1 9 Toothed lock washer 1 10 Toothed lock washer retainer 1 11 4th wheel gear 1 12 Collar 1 13 Washer 1 14 Circlip 1 15 6th wheel gear 1 16 Circlip 1 17 Washer 1 18 Collar 1 19 2nd wheel gear 1 20 Collar 1
TRANSMISSION 5-89 21 Oil seal 1 22 Bearing 1 23 Drive axle 1For assembly, reverse the disassem- bly procedure. Disassembling the drive axle assenbly Order Job/Parts to remove Q’ty Remarks
TRANSMISSION 5-90 EAS26250 REMOVING THE TRANSMISSION 1. Remove: Drive axle asseembly “1” Shift drum retainers “2” Shift fork guide bars Shift fork “L” and “R” Shift drum assembly Shift fork “C” 2. Remove: Bearing housing “1” Main axle assembly “2” ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Insert two bolts “3” of the proper size, as shown in the illustration, into the main axle assembly bearing housing. b. Tighten the bolts until they contact the crankcase surface. c. Continue tightening the bolts until the main axle assembly comes free from the upper crankcase. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3. Remove: Oil pipe “1” Bearing “2” EAS26260 CHECKING THE SHIFT FORKS The following procedure applies to all of the shift forks. 1. Check: Shift fork cam follower “1” Shift fork pawl “2”Bends/damage/scoring/wear → Replace the shift fork. 2. Check: Shift fork guide barRoll the shift fork guide bar on a flat sur- face. Bends → Replace. WARNING EWA12840 Do not attempt to straighten a bent shift fork guide bar.
TRANSMISSION 5-91 3. Check: Shift fork movement(along the shift fork guide bar) Rough movement → Replace the shift forks and shift fork guide bar as a set. EAS26270 CHECKING THE SHIFT DRUM ASSEMBLY 1. Check: Shift drum grooves “1” Damage/scratches/wear → Replace the shift drum assembly. Shift drum segment “2” Damage/wear → Replace the shift drum assembly. Shift drum bearing “3” Damage/pitting → Replace the shift drum assembly. EAS26280 CHECKING THE TRANSMISSION 1. Measure: Main axle runout (with a centering device and dial gauge “1”) Out of specification → Replace the main axle. 2. Measure: Drive axle runout(with a centering device and dial gauge “1”) Out of specification → Replace the drive axle. 3. Check: Transmission gears Blue discoloration/pitting/wear → Replace the defective gear(s). Transmission gear dogs Cracks/damage/rounded edges → Replace the defective gear(s). Main axle runout limit 0.08 mm (0.0032 in) Drive axle runout limit0.08 mm (0.0032 in)
TRANSMISSION 5-92 ET2D1022 INSTALLING THE TRANSMISSION 1. Install: Bearing “1” NOTE: Make the seal side of bearing face to the out- side and install it close to the right end face of the crankcase. Oil pipe “2” 2. Install: Main axle assembly “1” Bearing housing “2” Shift fork “C” Shift drum assembly Shift fork guide bar Shift fork guide bar retainer 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”. Carefully position the shift forks so that they are installed correctly into the transmission gears. Install shift fork “C” into the groove in the 3rd and 4th pinion gear on the main axle. 3. Install: Shift fork “L” “1” and “R” “2” Drive axle assembly “3” Shift fork guide bar Shift fork guide bar retainer “4” NOTE: Install shift fork “L” into the groove in the 6th wheel gear and shift fork “R” into the groove in the 5th wheel gear on the drive axle. Make sure that the drive axle bearing circlip “a” is inserted into the grooves in the upper crankcase.Bearing housing bolt12 Nm (1.2 m·kg, 8.7 ft·lb) LOCTITE® Shift fork guide bar retainer bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) LOCTITE® Shift fork guide bar retainer bolt10 Nm (1.0 m·kg, 7.2 ft·lb) LOCTITE®