Yamaha FZS6W 07 User Manual

CRANKSHAFT
5-72
g. Remove the lower crankcase and the crankshaft journal lower bearings.
h. Measure the compressed Plastigauge® 
width “c” on each crankshaft journal.
If the crankshaft-journal-to-crankshaft-jour-
nal-bearing clearance is out of specifica-
tion, select replacement crankshaft journal 
bearings.
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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...

CRANKSHAFT
5-73
 Be sure to install each crankshaft journal 
upper bearing in its original place.
2. Install:  Crankshaft
3. Install:  Lower crankcaseRefer to CRANKCASE on page 5-55. 

TRANSMISSION
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EAS26240
TRANSMISSION
Removing the transmission, shift drum assembly, and shift forks
Order Job/Parts to remove Q’ty RemarksLower crankcase 1 Refer to CRANKCASE on page 5-55.
1 Drive axle assembly 1
2 Circlip 1
3 Oil seal 1
4 Bearing 1
5 Shift drum retainer 1
6 Shift fork guide bar 2
7Spring 4
8 Shift fork-L 1
9 Shift fork-R 1
10 Shift drum assembly 1
11 Shift fork-C 1
12 Main axle assembly 1
13 Oil pipe 1
14 Oil baffle plate 1
15 Thrust plate 1
16 Washer 1 For installation, reverse...

TRANSMISSION
5-75
Disassembling the main axle assembly
Order Job/Parts to remove Q’ty Remarks1 Bearing 1
2 2nd pinion gear 1
3 Toothed lock washer 1
4 Toothed lock washer retainer 1
5 6th pinion gear 1
6 Collar 1
7 Washer 1
8 Circlip 1
9 3rd pinion gear 1
10 Circlip 1
11 Washer 1
12 5th pinion gear 1
13 Collar 1
14 Main axle 1
15 Bearing housing 1
16 Bearing 1
For installation, reverse the removal proce-
dure. 

TRANSMISSION
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Disassembling the drive axle assembly
Order Job/Parts to remove Q’ty Remarks1 Washer 1
2 1st wheel gear 1
3 Collar 1
4 5th wheel gear 1
5 Circlip 1
6 Washer 1
7 Collar 1
8 3rd wheel gear 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 2nd wheel gear 1
19 Collar 1
20 Collar 1
21 Oil seal 1
22 Bearing 1
23 Circlip 1
24 Drive axle 1 

TRANSMISSION
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For installation, reverse the removal proce-
dure.
Disassembling the drive axle assembly
Order Job/Parts to remove Q’ty Remarks 

TRANSMISSION
5-78
EAS26250
REMOVING THE TRANSMISSION
1. Remove: Main axle assembly “1”(with the Torx® wrench)
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a. Insert two bolts “2” 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.
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EAS26260
CHECKING THE SHIFT FORKS
The following...

TRANSMISSION
5-79
 Shift drum bearing “2”Damage/pitting  → Replace the shift drum 
assembly.
EAS26300
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...

TRANSMISSION
5-80
 Install shift fork-C into the groove in the 3rd 
and 4th pinion gear on the main axle.
3. Install:  Shift fork-R “1”
 Shift fork-L “2”
Drive axle “3”
 Shift fork guide bar
 Shift drum retainer
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. 4. Check:
TransmissionRough movement  →...

TRANSMISSION
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