User manual YAMAHA YZF-R7-1999

[. . . ] OWNER'S SERVICE MANUAL YZF-R7 5FL-28199-E0 EC010010 YZF-R7 OWNER'S SERVICE MANUAL ©1999 by Yamaha Motor Co. , Ltd. 1st Edition, December 1998 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Co. , Ltd. Printed in Japan EAU00001 INTRODUCTION Welcome to the Yamaha world of motorcycling! [. . . ] Install: · generator rotor cover NOTE: Tighten the generator rotor cover bolts in stages and in a crisscross pattern. 4 - 34 PICKUP COIL PICKUP COIL ENG 45 Nm (4. 5 m · kg, 32 ft · Ib) 12 Nm (1. 2 m · kg, 8. 7 ft · Ib) T. R. E (6) LT 6 5 4 Nm (0. 4 m · kg, 2. 9 ft · Ib) T. 15 Nm (1. 5 m · kg, 11 ft · Ib) Order Job/Part Removing the pickup coil and pickup coil rotor Fuel tank Bottom cowling and front cowling Engine oil Q'ty Remarks Remove the parts in the order listed. Refer to "FUEL TANK AND AIR FILTER" in chapter 3. Refer to "COWLINGS" in chapter 3. Refer to "CHANGING THE ENGINE OIL" in chapter 3. Refer to "GENERATOR". 1 2 3 4 Generator rotor cover Pickup coil lead holder Pickup coil rotor cover Pickup coil rotor cover gasket Dowel pin 1 1 1 2 4 - 35 LT LT T. R. T. 1 2 3 New 7 4 4 LT R. R. PICKUP COIL ENG 45 Nm (4. 5 m · kg, 32 ft · Ib) 12 Nm (1. 2 m · kg, 8. 7 ft · Ib) T. R. E (6) LT 6 5 4 Nm (0. 4 m · kg, 2. 9 ft · Ib) T. 15 Nm (1. 5 m · kg, 11 ft · Ib) Order Job/Part 5 Pickup coil coupler 6 Pickup coil 7 Pickup coil rotor Q'ty Remarks 1 Disconnect. 1 1 For installation, reverse the removal procedure. 4 - 36 LT LT T. R. T. 1 2 3 New 7 4 4 LT R. R. PICKUP COIL 1 2 ENG 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. 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 1 INSTALLING THE PICKUP COIL ROTOR 1 a 2 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. CAUTION: ACHTUNG: Lubricate the pickup coil rotor bolt threads with engine oil. 4 - 37 PICKUP COIL ENG 2. Tighten: · pickup coil rotor bolt 1 45 Nm (4. 5 m · kg, 32 ft · lb) 1 NOTE: While holding the generator rotor 2 with the rotor holding tool 3, tighten the pickup coil rotor bolt. Apply: · sealant (onto the pickup coil lead grommet) Yamaha bond No. 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 pattern. T. R. 4 - 38 CLUTCH EB405000 ENG CLUTCH Order Job/Part Removing the clutch cover Bottom cowling and front cowling Engine oil Q'ty Remarks Remove the parts in the order listed. Refer to "COWLINGS" in chapter 3. Refer to "CHANGING THE ENGINE OIL" in chapter 3. 1 2 3 Clutch cover Clutch cover gasket Dowel pin 1 1 2 For installation, reverse the removal procedure. 4 - 39 CLUTCH ENG Order 1 2 3 4 5 6 7 8 9 10 11 12 13 Job/Part Removing the clutch Clutch spring plate retainer Clutch spring plate Clutch spring plate seat Pressure plate Push rod #1 Ball Push rod #2 Friction plate #1 Clutch plate Friction plate #2 Lock washer Clutch boss Thrust washer Q'ty 1 1 1 1 1 1 1 8 8 1 1 1 1 Remarks Remove the parts in the order listed. 3. 00 mm (0. 12 in) 3. 85 mm (0. 15 in) 4 - 40 CLUTCH ENG Order 14 15 16 17 18 19 20 21 22 23 24 25 Job/Part Back torque limiter outer boss Back torque limiter bearing Back torque limiter inner boss Thrust plate Thrust washer Clutch housing Bearing Starter clutch gear Bearing Starter clutch assembly Circlip Starter clutch idle gear Q'ty 1 1 1 1 1 1 1 1 1 1 1 1 Remarks For installation, reverse the removal procedure. 4 - 41 CLUTCH EB405102 ENG REMOVING THE CLUTCH 1 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. 2. 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. Check: · friction plate Damage/wear Replace the friction plates as a set. [. . . ] CO, diagnosis switch box method Press the UP switch eight times within four seconds to clear the condition code record from the ROM. Test coupler adapter method Remove the rear cowling. Disconnect the relay unit coupler from the relay unit. Press the start switch ten times within four seconds to clear the condition code record from the ROM. [. . . ]