YAMAHA YZF-R7 1999 Owners Manual

ENG
4 - 39
CLUTCH
EB405000
CLUTCH
Order Job/Part Q’ty Remarks
Removing the clutch coverRemove the parts in the order listed.
Bottom cowling and front cowling Refer to “COWLINGS” in chapter 3.
Engine oil Drain.
Refer to “CHANGING THE ENGINE
OIL” in chapter 3.
1 Clutch cover 1
2 Clutch cover gasket 1
3 Dowel pin 2
For installation, reverse the removal
procedure.

ENG
4 - 40
CLUTCH
Order Job/Part Q’ty Remarks
Removing the clutchRemove the parts in the order listed.
1 Clutch spring plate retainer 1
2 Clutch spring plate 1
3 Clutch spring plate seat 1
4 Pressure plate 1
5 Push rod #1 1
6 Ball 1
7 Push rod #2 1
8 Friction plate #1 8 3.00 mm (0.12 in)
9 Clutch plate 8
10 Friction plate #2 1 3.85 mm (0.15 in)
11 Lock washer 1
12 Clutch boss 1
13 Thrust washer 1

ENG
4 - 41
CLUTCH
Order Job/Part Q’ty Remarks
14 Back torque limiter outer boss 1
15 Back torque limiter bearing 1
16 Back torque limiter inner boss 1
17 Thrust plate 1
18 Thrust washer 1
19 Clutch housing 1
20 Bearing 1
21 Starter clutch gear 1
22 Bearing 1
23 Starter clutch assembly 1
24 Circlip 1
25 Starter clutch idle gear 1
For installation, reverse the removal
procedure.

4 - 42
ENGCLUTCH
EB405102
REMOVING THE CLUTCH
1. Remove:
• clutch cover 1
NOTE:
Loosen each bolt 1/4 of a turn at a time,
in stages and in a crisscross pattern.
After all of the bolts are fully loosened,
remove them.
1
1

2. Straighten the lock washer tab.
3. Loosen:
• clutch boss nut 1
NOTE:
While holding the clutch boss 2 with
the clutch holding tool 3, loosen the
clutch boss nut.
Clutch holding tool
90890-04086
EB405400
CHECKING THE FRICTION PLATES
The following procedure applies to all of
the friction plates.
1. Check:
• friction plate
Damage/wear ® Replace the friction
plates as a set.
2. Measure:
• friction plate thickness
Out of specification ® Replace the fric-
tion plates as a set.
NOTE:
Measure the friction plate at four places.
Friction plate #1 thickness
2.9 ~ 3.1 mm
(0.114 ~ 0.122 in)
: 2.8 mm (0.110 in)
Friction plate #2 thickness
3.7 ~ 3.9 mm
(0.146 ~ 0.154 in)
: 3.6 mm (0.142 in)

4 - 43
ENGCLUTCH
EB405410
CHECKING THE CLUTCH PLATES
The following procedure applies to all of
the clutch plates.
1. Check:
• clutch plate
Damage ® Replace the clutch plates
as a set.
2. Measure:
• clutch plate warpage
(with a surface plate and thickness
gauge 1)
Out of specification ® Replace the
clutch plates as a set.
Maximum clutch plate
warpage
0.1 mm (0.004 in)
EB405430
CHECKING THE CLUTCH SPRING PLATE
1. Check:
• clutch spring plate
Damage ® Replace.
2. Check:
• clutch spring plate seat
Damage ® Replace.
EB405440
CHECKING THE CLUTCH HOUSING
1. Check:
• clutch housing dogs
Damage/pitting/wear ® Deburr the
clutch housing dogs or replace the
clutch housing.
NOTE:
Pitting on the clutch housing dogs will
cause erratic clutch operation.
2. Check:
• bearing
Damage/wear ® Replace the clutch
housing.

4 - 44
ENGCLUTCH
EB405450
CHECKING THE CLUTCH BOSS
1. Check:
• clutch boss splines
Damage/pitting/wear ® Replace the
clutch boss.
NOTE:
Pitting on the clutch boss splines will
cause erratic clutch operation.
EB405460
CHECKING THE PRESSURE PLATE
1. Check:
• pressure plate 1
Cracks/damage ® Replace.
• bearing 2
Damage/wear ® Replace.
CHECKING THE PUSH RODS AND BALL
1. Check:
• push rod #1 1
• push rod #2 2
• ball 3
Damage/wear ® Replace the pull rods
and ball as a set.
2. Check:
• push rod bearing 4
Damage/wear ® Replace.
CHECKING THE BACK TORQUE LIMITER
1. Check:
• back torque limiter outer boss splines
Damage/pitting/wear ® Replace the
back torque limiter outer boss.

4 - 45
ENGCLUTCH
2. Check:
• back torque limiter clutch
t t t t t t t t t t t t t t t t t t t t t t t t t t t
a. Install the back torque limiter bearing
and back torque limiter outer boss
onto the back torque limiter inner
boss and hold the back torque limiter
inner boss.
b. When turning the back torque limiter
outer boss clockwise , the back
torque limiter inner boss and back
torque limiter outer boss should
engage, otherwise the back torque
limiter is faulty and must be replaced.
c. When turning the back torque limiter
outer boss counterclockwise õ, it
should turn freely, otherwise the back
torque limiter is faulty and must be
replaced.
s s s s s s s s s s s s s s s s s s s s s s s s s s s
CHECKING THE STARTER CLUTCH
1. Check:
• starter clutch gear
• starter clutch idle gear
Chips/pitting/roughness/wear ®
Replace the defective part(-s).
2. Check:
• starter clutch operation
t t t t t t t t t t t t t t t t t t t t t t t t t t t
a. Install the starter clutch gear 1 onto
the starter clutch2 and hold the
starter clutch.
b. When turning the starter clutch gear
clockwise , the starter clutch and
the starter clutch gear should engage,
otherwise the starter clutch is faulty
and must be replaced.
c. When turning the starter clutch gear
counterclockwise õ, it should turn
freely, otherwise the starter clutch is
faulty and must be replaced.
s s s s s s s s s s s s s s s s s s s s s s s s s s s

4 - 46
ENGCLUTCH
EB405703
INSTALLING THE CLUTCH
1. Install:
• clutch housing
NOTE:
• Make sure that the slots a in the
clutch housing align with the tabs b
on the oil/water pump assembly drive
sprocket.
• Make sure that the primary driven gear
teeth and primary drive gear teeth
mesh correctly.
• Make sure that the starter clutch gear
teeth and starter clutch idle gear teeth
mesh correctly.
2. Install:
• back torque limiter inner boss 1
• back torque limiter bearing 2
• back torque limiter outer boss 3
ACHTUNG:CAUTION:
Be sure that the back torque limiter
bearing is installed facing in the correct
direction as shown.
3. Install:
• lock washer
• clutch boss nut 1
NOTE:
While holding the clutch boss 2 with
the clutch holding tool 3, tighten the
clutch boss nut.
Clutch holding tool
90890-04086
New
T R..70 Nm (7.0 m · kg, 50 ft · lb)

4 - 47
ENGCLUTCH
4. Bend the lock washer tab along a flat
side of the nut.
5. Lubricate:
• friction plates
• clutch plates
(with the recommended lubricant)
Recommended lubricant
Engine oil
6. Install:
• friction plates 1 - 3.00 mm (0.12 in)
• clutch plates 2
• friction plate 3 - 3.85 mm (0.15 in)
NOTE:
First, install a friction plate and then
alternate between a clutch plate and a
friction plate.
13
2

ENG
4 - 48
SHIFT SHAFT
EB408000
SHIFT SHAFT
Order Job/Part Q’ty Remarks
Removing the shift shaft and stop-
per leverRemove the parts in the order listed.
Drive sprocket cover Refer to “ENGINE”.
1 Shift shaft cover 1
2 Shift shaft cover gasket 1
3 Dowel pin 2
4 Shift shaft 1
5 Shift shaft spring 1
6 Spacer 1
7 Stopper lever spring 1
8 Stopper lever 1
9 Circlip 1
10 Collar 1
11 Shift shaft spring stopper 1
For installation, reverse the removal
procedure.