1999 YAMAHA YZF-R7 Owners Manual

4 - 37
ENG

PICKUP COIL
REMOVING THE PICKUP COIL ROTOR
1. Remove:
• pickup coil lead holder
1

• pickup coil rotor cover
2

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.
2
2
1

1

2. Remove:
• pickup coil rotor bolt
1

• washer
• pickup coil rotor
2

NOTE:

While holding the generator rotor
3
with the rotor holding tool
4, loosen the
pickup coil rotor bolt.
Rotor holding tool
90890-01235
2
2

1

1

INSTALLING THE PICKUP COIL ROTOR
1. Install:
• pickup coil rotor 1
• washer
• pickup coil rotor bolt
NOTE:
When installing the pickup coil rotor,
align the groove 2 in the crankshaft
sprocket with the projection a in the
pickup coil rotor.
ACHTUNG:CAUTION:
Lubricate the pickup coil rotor bolt
threads with engine oil.
1
1

2

2
a
a

4 - 38
ENGPICKUP COIL
2. Tighten:
• pickup coil rotor bolt 1
NOTE:
While holding the generator rotor 2
with the rotor holding tool 3, tighten
the pickup coil rotor bolt.
Rotor holding tool
90890-01235
1
1

T R..45 Nm (4.5 m · kg, 32 ft · lb)
3. Apply:
• sealant
(onto the pickup coil lead grommet)
Yamaha bond No. 1215
90890-85505
4. Install:
• pickup coil rotor cover
• pickup coil lead holder
• clutch cable holder
NOTE:
• When installing the pickup coil rotor
cover, align the timing chain guide
(intake side) pin 1 of the with the hole
2 in the pickup coil rotor cover.
• Tighten the pickup coil rotor cover
bolts in stages and in a crisscross pat-
tern.
2
2
1

1

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.