1999 YAMAHA YZF-R7 clutch

3 - 28
CHK
ADJBLEEDING THE HYDRAULIC CLUTCH SYSTEM/
CLEANING THE AIR FILTER ELEMENT
j. Tighten the bleed screw to specifica-
tion.
k. Fill the clutch fluid reservoir to the
proper level with the recommended
clutch fluid.
Refer to “CHECKING THE CLUTCH
FLUID LEVEL”.
WARNINGWARNING
After bleeding the hydraulic clutch sys-
tem, check the clutch operation.
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..
Bleed screw
6 Nm (0.6 m • kg, 4.3 ft • lb)
EB303130
CLEANING THE AIR FILTER ELEMENT
1. Remove:
• fuel tank
• air filter case cover
• air filter element
Refer to “FUEL TANK AND AIR FIL-
TER”.
2. Clean:
• air filter element
Apply compressed air to the outer sur-
face of the air filter element.
3. Check:
• air filter element
Damage ® Replace.
4. Install:
• air filter element
• air filter case cover
ACHTUNG:CAUTION:
Never operate the engine without the
air filter element installed. Unfiltered air
will cause rapid wear of engine parts
and may damage the engine. Operating
the engine without the air filter element
will also affect the electronic fuel injec-
tion, leading to poor engine perfor-
mance and possible overheating.
5. Install:
• fuel tank
Refer to “FUEL TANK AND AIR FIL-
TER”.

3 - 44
CHK
ADJ
CHECKING AND ADJUSTING THE STEERING HEAD
3. Remove:
• bottom cowling
• front cowling
Refer to “COWLINGS”.
4. Remove:
• front brake fluid reservoir 1
• clutch fluid reservoir 2
2
2
1
1

5. Loosen:
• upper bracket pinch bolts 1
• handlebar pinch bolts 2
6. Remove:
• upper bracket bolts 3
• handlebars
(from the upper bracket)
1
1

3
3

2

2

7. Remove:
• steering stem nut 1
• washer 2
• upper bracket 3
2
2
1
1
3
3

8. Adjust:
• steering head
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. Remove the lock washer 1, the upper
ring nut 2, and the rubber washer 3.
b. Loosen the lower ring nut 4 and then
tighten it to specification with a ring
nut wrench 5.
NOTE:
Set the torque wrench at a right angle to
the steering nut wrench.
Steering nut wrench
90890-01403
T R..
Lower ring nut (initial tighten-
ing torque)
18 Nm (1.8 m • kg, 13 ft • lb)

ENG

4 - 1
ENGINE
EB400011
OVERHAULING THE ENGINE
ENGINE
T R..70 Nm (7.0 m • kg, 50 ft • Ib)
T R..10 Nm (1.0 m • kg, 7.2 ft • Ib)
T R..10 Nm (1.0 m • kg, 7.2 ft • Ib)
LTLT
1 3
2 1314
128 5 46791110
1
New

Order Job/Part Q’ty Remarks
Removing the drive sprocket
Remove the parts in the order listed.
Bottom cowling and front cowling Refer to “COWLINGS” in chapter 3.
1 Locknut 2 Loosen.
2 Shift rod 1
3 Shift arm 1
4 Starter cable 1
5 Starter knob 1
6 Clutch release cylinder 1
7 Dowel pin 2
4

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)