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 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, than the bearing size for 
“J
1” is:
EAS4S81040
INSTALLING THE CRANKSHAFT
1. Install:
 Crankshaft journal upper bearings “1”(into the upper crankcase)
NOTE:
 Align the projections “a” on the crankshaft journal upper bearings with the notches “b” in 
the upper crankcase.
“J1” (crankcase) – “J1”
(crankshaft web) – 1 =
6 – 2 – 1 = 3 (brown)
CRANKSHAFT JOURNAL BEARING  COLOR CODE
0 White
1Blue
2Black
3Brown
4 Green 
						

							
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
5-74
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 the removal proce-
dure. 
						

							
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
5-76
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
5-77
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 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.
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 grooveDamage/scratches/wear  → Replace the 
shift drum assembly.
 Shift drum segment “1”
Damage/wear  → Replace the shift drum 
assembly. 
						

							
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 Cracks/damage/rounded edges  → Replace 
the defective gear(s).
4. Check:  Transmission gear engagement(each pinion gear to its respective wheel 
gear)
Incorrect  → Reassemble the transmission 
axle assemblies.
5. Check:  Transmission gear movementRough movement  → Replace the defective 
part(s).
6. Check: Circlips
Bends/damage/looseness  → Replace.
EAS26350
INSTALLING THE TRANSMISSION
1. Install:
 Oil pipe “1”
 Main axle assembly “2”(with the Torx® wrench)
NOTE:
Make sure to caulk the bolts at three positions 
after installing the bearing housing.
2. Install:
 Shift fork-C “3”
 Shift drum assembly “4”
 Shift fork guide bar
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.
Main axle runout limit0.02 mm (0.0008 in)
Drive axle runout limit
0.02 mm (0.0008 in) 
						

							
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  → Repair.
NOTE:
Oil each gear, shaft,  and bearing thoroughly.
Shift drum retainer bolt
10 Nm (1.0 m·kg, 7.2 ft·lb)
LOCTITE® 
						

							
TRANSMISSION
5-81