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 resistances (commuta-
tor and insulation)
Out of specification → Replace the starter 
motor.
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a. Measure the armature assembly resis-
tances with the pocket tester.b. If any resistance is out of specification, 
replace the starter motor.
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5. Measure:
 Brush length “a”
Out of specification → Replace the brushes 
as a set.
6. Measure:
 Brush spring force
Out of specification → Replace the brush 
springs as a set.
Limit
23.5 mm (0.93 in)
Mica undercut (depth)
1.50 mm (0.06 in)
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
Armature coil
Commutator resistance “1”
0.009–0.011 Ω at 20°C (68°F)
Insulation resistance “2”
Above 1 MΩ at 20°C (68°F)
Limit
7.19 mm (0.28 in)
Brush spring force
5.28–7.92 N (19.01–28.51 oz)
(538–808 gf) 
						

							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 the tab “a” on the brush holder “2” with 
the tab “b” in the starter motor rear cover.3. Install:
Nut “1”
4. Install:
 Starter motor yoke “1”
 Gasket “2” 
 Starter motor rear cover “3”
 Starter motor assembling bolts “4”
NOTE:
Align the match marks “a” on the starter motor 
yoke with the match marks “b” on the front and 
starter motor rear covers.
New
Nut
5 Nm (0.5 m·kg, 3.6 ft·lb)
Starter motor assembling bolt
5 Nm (0.5 m·kg, 3.6 ft·lb)
New 
						

							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 seat
5. Straighten the clutch boss nut rib “1”.
6. Loosen:
 Clutch boss nut “1”
NOTE:
While holding the clutch boss “2” with the uni-
versal clutch holder “3”, loosen the clutch boss 
nut.
7. Remove:
 Clutch boss nut
Universal clutch holder
90890-04086
YM-91042 
						

							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 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.3. Measure:
 assembly width “a” of the friction plates and 
clutch plates
Out of specification → Adjust.
NOTE:
Perform the thickness measurement without 
applying the oil.
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a. Assembly width adjusted by clutch plate “1” 
and “2”.
b. Select the clutch plate from the following 
table.
Clutch plate “1”
Friction plate thickness
2.90–3.10 mm (0.114–0.122 in)
Wear limit
2.80 mm (0.1102 in)
Warpage limit
0.10 mm (0.0039 in)
Assembly width
42.4–43.0 mm (1.67–1.69 in)
Part No. Thickness
4B1-16324-00 1.6 mm (0.062 in)
5VY-16325-00 2.0 mm (0.079 in) STD
4B1-16325-00 2.3 mm (0.091 in) 
						

							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 “a”
Out of specification → Replace the clutch 
springs as a set.
EAS25150
CHECKING THE CLUTCH HOUSING
1. Check:
 Clutch housing dogs
Damage/pitting/wear → Deburr the clutch 
housing dogs or replace the clutch hous-
ing.
NOTE:
Pitting on the clutch housing dogs will cause 
erratic clutch operation.
2. Check:
 Bearing
Damage/wear → Replace the bearing and 
clutch housing.
EAS25160
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.
2. Check:
Clutch boss
Cracks/damage → Replace. Part No. Thickness
5VY-16325-00 2.0 mm (0.079 in) STD
4B1-16325-00 2.3 mm (0.091 in)
Clutch spring free length
43.80 mm (1.72 in)
Limit
41.61 mm (1.64 in) 
						

							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
INSTALLING THE CLUTCH
1. Install:
 Clutch housing “1”
 Conical spring washer
 Thrust plate 2
NOTE:
Align the projection of clutch housing “a” and 
hollow of the oil pump drive gear “b”.
2. Install:
 Pressure plate 2 “1”
 Clutch boss “2”
NOTE:
Fit the groove “a” of the pressure plate 2 to the 
projection “b” of the clutch boss to assemble.