lock YAMAHA YZF-R7 1999 Owner's Guide

4 - 14
ENGCAMSHAFTS
2. Check:
• camshaft sprocket
More than 1/4 tooth wear a ® Replace
the camshaft sprockets and the timing
chain as a set.
a1/4 tooth
bCorrect
1Timing chain roller
2Camshaft sprocket
3. Check:
• timing chain guide (exhaust side) 1
• timing chain guide (intake side) 2
• timing chain guide (top side) 3
Damage/wear ® Replace the defective
part(-s).
EB401430
CHECKING THE TIMING CHAIN
TENSIONER
1. Check:
• timing chain tensioner
Cracks/damage/rough movement ®
Replace.
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. Lightly press the timing chain ten-
sioner rod into the timing chain ten-
sioner housing by hand.
NOTE:
While pressing the timing chain ten-
sioner rod, wind it clockwise with a thin
screwdriver 1 until it stops.
b. Remove the screwdriver and slowly
release the timing chain tensioner
rod.
c. Make sure that the timing chain ten-
sioner rod comes out of the timing
chain tensioner housing smoothly. If
there is rough movement, replace the
timing chain tensioner.
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 - 15
ENGCAMSHAFTS
EB401701
INSTALLING THE CAMSHAFTS
1. Install:
• timing chain guide (intake side)
2. Install:
• camshaft sprockets 1
(with the flywheel puller 2)
3. Install:
• exhaust camshaft
• intake camshaft
• exhaust camshaft caps
• intake camshaft caps
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. Turn the crankshaft clockwise.
b. When piston #1 is at TDC on the com-
pression stroke, align the TDC a
mark on the pickup coil rotor with the
crankcase mating surface b.
c. Install the timing chain onto both
camshaft sprockets and then install
the camshaft sprockets onto the cam-
shafts.
ACHTUNG:CAUTION:
Do not turn the crankshaft when install-
ing the camshaft to avoid damage or
improper valve timing.
NOTE:
Make sure that the punch marks c on
the camshafts face up.
d. Install the exhaust and intake cam-
shaft caps.
NOTE:
Make sure that the punch marks c on
the camshafts are aligned with the
arrow marks d on the camshaft caps.
Out of alignment ® Reinstall.
e. Remove the wire from the timing
chain.
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
Flywheel puller
90890-01080
T R..
Camshaft cap bolt
10 Nm (1.0 m • kg, 7.2 ft • lb)
T R..24 Nm (2.4 m · kg, 17 ft · lb)
H H
T
T
a
a
b
b

4 - 16
ENGCAMSHAFTS
4. Install:
• timing chain guide (exhaust side)
5. Install:
• timing chain tensioner
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. Lightly press the timing chain ten-
sioner rod into the timing chain ten-
sioner housing by hand.
b. While pressing the timing chain ten-
sioner rod, wind it clockwise with a
thin screwdriver 1 until it stops.
c. With the screwdriver still inserted
into the timing chain tensioner, install
the timing chain tensioner and gasket
onto the cylinder block. Then, tighten
the timing chain tensioner bolts to the
specified torque.
WARNINGWARNING
Always use a new gasket.
NOTE:
The “UP” mark on the timing chain ten-
sioner should face up.
d. Remove the screwdriver, make sure
that the timing chain tensioner rod
releases, and tighten the cap bolt to
the specified torque.
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
T R..
Timing chain tensioner bolt
10 Nm (1.0 m • kg, 7.2 ft • lb)
T R..
Cap bolt
10 Nm (1.0 m • kg, 7.2 ft • lb)
6. Turn:
• crankshaft
(several turns counterclockwise)

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

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 - 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

4 - 49
ENGSHIFT SHAFT
EB408401
CHECKING THE SHIFT SHAFT
1. Check:
• shift shaft 1
Bends/damage/wear ® Replace.
• shift shaft spring 2
Damage/wear ® Replace.
EB408410
CHECKING THE STOPPER LEVER
1. Check:
• stopper lever 1
Bends/damage ® Replace.
Roller turns roughly ® Replace the
stopper lever.
EB408703
INSTALLING THE SHIFT SHAFT
1. Install:
• shift shaft spring stopper 1
• stopper lever spring 2
• stopper lever 3
NOTE:
• Apply locking agent (LOCTITE®) to the
threads of the shift shaft spring stop-
per.
• Hook the ends of the stopper lever
spring onto the stopper lever and the
crankcase boss.
• Mesh the stopper lever with the shift
drum segment assembly.
T R..22 Nm (2.2 m · kg, 16 ft · lb)
2. Install:
• shift shaft 1
• spacer
NOTE:
• Lubricate the oil seal lips with lithium
soap base grease.
• Install the end of the shift shaft spring
onto the shift shaft spring stopper 2.

ENG
4 - 81
TRANSMISSION
Order Job/Part Q’ty Remarks
Disassembling the main axle assem-
blyRemove the parts in the order listed.
1 2nd pinion gear 1
2 Toothed lock washer 1
3 Toothed lock washer retainer 1
4 6th pinion gear 1
5 Toothed spacer 1
6 Toothed washer 2
7 Circlip 2
8 3rd/4th pinion gears 1
9 5th pinion gear 1
@ Collar 1