Yamaha Yzf R1 2007 Manual

ELECTRIC STARTER
5-41
EAS24790
CHECKING THE STARTER MOTOR
1. Check:
Commutator
Dirt → Clean with 1000 grit sandpaper.
2. Measure:
 Commutator diameter “a”
Out of specification → Replace the starter 
motor.
3. Measure:
 Mica undercut “a”
Out of specification → Scrape the mica to 
the proper measurement with a hacksaw 
blade that has been grounded to fit the 
commutator.
NOTE:
The mica of the commutator must be undercut 
to ensure proper operation of the commutator.
4. Measure:
 Armature assembly...

ELECTRIC STARTER
5-42
7. Check:
 Gear teeth
Damage/wear → Replace the starter 
motor.
EAS24800
ASSEMBLING THE STARTER MOTOR
1. Install:
 Brush holder
 Armature
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a. Pull both the brush spring and the brush 
outside and hook the brush spring to the 
groove portion at the side of the brush.
b. Insert the armature into the brush holder 
and push the brush inside until it touches 
the armature.
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2. Install:
 O-rings 
 Rear cover “1”
NOTE:
Align...

ELECTRIC STARTER
5-43
EAS24810
INSTALLING THE STARTER MOTOR
1. Install:
 Starter motor “1”
 Starter motor bolts “2”
2. Connect:
 Starter motor lead “3”
Starter motor bolt
10 Nm (1.0 m·kg, 7.2 ft·lb)
Starter motor lead bolt
7 Nm (0.7 m·kg, 5.1 ft·lb) 

CLUTCH
5-44
EAS25060
CLUTCH
Removing the clutch cover
Order Job/Parts to remove Q’ty Remarks
Right side cowling Refer to GENERAL CHASSIS on page 4-1.
Bottom cowlings Refer to GENERAL CHASSIS on page 4-1.
Engine oilDrain.
Refer to CHANGING THE ENGINE OIL on 
page 3-11.
1Cover 1
2 Clutch cable 1 Disconnect.
3Clutch cover 1
4 Clutch cover gasket 1
5Dowel pin 2
6 Oil filler cap 1
For installation, reverse the removal proce-
dure. 

CLUTCH
5-45
Removing the push lever shaft
Order Job/Parts to remove Q’ty Remarks
1 Circlip 2
2 Pull lever 1
3 Pull lever spring 1
4 Pull lever shaft 1
5 Oil seal 1
6 Bearing 2
For installation, reverse the removal proce-
dure. 

CLUTCH
5-46
Removing the clutch
Order Job/Parts to remove Q’ty Remarks
1 Compression spring 6
2 Pressure plate 1 1
3Push rod 1
4 Bearing 1
5 Friction plate 1 1
6 Clutch plate 1 1
7 Friction plate 2 7
8 Clutch plate 2 1
9 Clutch plate 3 6
10 Friction plate 3 1
11 Clutch damper spring 1
12 Clutch damper spring seat 1
13 Muffler 1
14 Spring 3
15 Clutch boss 1
16 Pressure plate 2 1
17 Conical spring washer 1
18 Thrust plate 2 1
19 Clutch housing 1
20 Bearing 1
For installation, reverse the removal proce-
dure. 

CLUTCH
5-47
EAS25080
REMOVING THE CLUTCH
1. Remove:
 Clutch cover “1”
Gasket
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. Remove:
 Compression spring bolts “1”
 Compression springs
 Pressure plate “2”
 Push rod “3”
3. Remove:
 Friction plate 1 “1”
4. Remove:
 Clutch plate 1 “1” Friction plate 2
 Clutch plate 2
 Clutch plate 3
 Friction plate 3
 Clutch damper spring
 Clutch damper spring...

CLUTCH
5-48
 Springs
 Pressure plate 2
 Conical spring washer
 Thrust plate 2
EAS25100
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 friction 
plates as a set.
NOTE:
Measure the friction plate at four places.
EAS25110
CHECKING THE CLUTCH PLATES
The following procedure applies to all of the 
clutch...

CLUTCH
5-49
Clutch plate “2”
NOTE:
When adjusting the clutch assembly width [by 
replacing the clutch plate(s)], be sure to 
replace the clutch plate “1” fast.
After replacing the clutch plate “1”, if specifica-
tions cannot be met, replace the clutch plate 
“2”.
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EAS25140
CHECKING THE CLUTCH SPRINGS
The following procedure applies to all of the 
clutch springs.
1. Check:
Clutch spring
Damage → Replace the clutch springs as a 
set.
2. Measure:
 Clutch spring free length...

CLUTCH
5-50
EAS4C81005
CHECKING THE PRESSUR PLATE 2
1. Check:
 Pressure plate 2
Cracks / damage → Replace.
EAS25170
CHECKING THE PRESSURE PLATE 1
1. Check:
 Pressure plate “1”
Cracks/damage → Replace.
 Bearing “2”
Damage/wear → Replace.
EAS4C81006
CHECKING THE PUSH LEVER SHAFT AND 
PUSH ROD
1. Check:
 Push lever shaft pinion gear teeth “1”
 Push rod teeth “2”
Damage/wear → Replace the push rod and 
push lever shaft pinion gear as a set.2. Check:
 Push rod bearing
Damage/wear → Replace.
EAS25240...