1999 YAMAHA YZF-R7 Owners Manual

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.

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 - 50
OIL PAN AND OIL PUMP
EB411000
OIL PAN AND OIL PUMP
Order Job/Part Q’ty Remarks
Removing the oil pan and oil pumpRemove the parts in the order listed.
Engine oil Drain.
Refer to “CHANGING THE ENGINE
OIL” in chapter 3.
Coolant Drain.
Refer to “CHANGING THE COOLANT”
in chapter 3.
Radiator assembly and water pump
outlet pipeRefer to “RADIATOR AND THERMO-
STAT” and “OIL COOLER” in chapter 5.
Exhaust pipe assembly Refer to “ENGINE”.
1 Oil level switch connector 1 Disconnect.
2 Oil level switch 1
3 Oil level switch lead holder 1
4 Oil pan 1
5 Oil pan gasket 1
6 Dowel pin 2

ENG
4 - 51
OIL PAN AND OIL PUMP
EB411001
Order Job/Part Q’ty Remarks
7 Drain pipe 1
8 Oil strainer 1
9 Oil pipe 1
10 Oil delivery pipe 1
11 Dowel pin 1
12 Oil/water pump assembly 1
13 Relief valve assembly 1
For installation, reverse the removal
procedure.

ENG
4 - 52
OIL PAN AND OIL PUMP
EB411003
Order Job/Part Q’ty Remarks
Removing the oil pumpRemove the parts in the order listed.
1 Oil/water pump assembly driven
sprocket1
2 Washer 1
3 Oil pump housing 1
4 Bearing 1
5 Pin 2
6 Oil pump outer rotor 1
7 Oil pump inner rotor 1
8 Pin 1
For installation, reverse the removal
procedure.