Yamaha Yzf R1 2007 Manual

							CLUTCH
5-51
3. Install:
 Spring “1”
 Clutch boss nut “2” 
NOTE:
 Put the spring detent “a” into the groove of 
the pressure plate 2.
Assemble so that each spring detent “a” is 
positioned in a different groove.
 While holding the clutch boss “3” with the 
clutch holding tool “4”, tighten the clutch boss 
nut.
 Lock the threads on the clutch boss nut by 
staking them with a drift punch at the point 
aligned with the groove in the axle.4. Install:
 Clutch damper spring seat “1”
 Clutch damper spring “2”
NOTE:
Install the clutch damper spring as shown in 
the illustration.
5. Lubricate:
 Friction plates
 Clutch plates
(with the recommended lubricant)
6. Install:
 Friction plate 3
 Friction plate 2
 Clutch plate 3
 Clutch plate 2
 Clutch plate 1 “1”
Clutch boss nut
115 Nm (11.5 m·kg, 83 ft·lb)
Universal clutch holder
90890-04086
YM-91042
New
Recommended lubricant
Engine oil 
						

							CLUTCH
5-52
NOTE:
Assemble the friction plates and clutch plates 
according to the installation order.
7. Install:
 Friction plate 1 “1”
NOTE:
Install the last friction plate shifting half phase 
with the ø2 punch mark “2”.
8. Install:
 Bearing
 Pull rod
 Pressure plate 1 “1”
9. Install:
 Clutch springs
 Clutch spring bolts “1”
NOTE:
Tighten the clutch spring bolts in stages and in 
a crisscross pattern.
10. Install:
 Push lever
NOTE:
Install the push lever with the “h” mark facing 
toward upper side.
11. Install:
Clutch cover
 Clutch cover gasket
NOTE:
 Install the push rod so that the teeth a face 
towards the rear of the vehicle. Then, install 
the clutch cover.
 Apply oil onto the bearing.
 Apply molybdenum disulfide grease onto the 
push rod.
 When installing the clutch cover, push the 
push lever and check that the punch mark “a” 
on the push lever aligns with the mark “b” on 
the clutch cover. Make sure that the push rod 
teeth and push lever shaft pinion gear are 
engaged.
Clutch spring bolt
10 Nm (1.0 m·kg, 7.2 ft·lb) 
						

							CLUTCH
5-53
12. Tighten:
 Clutch cover bolts “1”
 Clutch cover bolt “2”
NOTE:
Tighten the clutch cover bolts in a stages and 
in a crisscross pattern.
13. Adjust:
 Clutch cable free play
Refer to ADJUSTING THE CLUTCH 
CABLE FREE PLAY on page 3-14.
Clutch cover bolt
12 Nm (1.2 m·kg, 8.7 ft·lb)
Clutch cover bolt
12 Nm (1.2 m·kg, 8.7 ft·lb)
LOCTITE® 
						

							SHIFT SHAFT
5-54
EAS25410
SHIFT SHAFT
Removing the shift shaft and stopper lever
Order Job/Parts to remove Q’ty Remarks
Shift arm  Refer to ENGINE REMOVAL on page 5-1
Clutch assembly Refer to CLUTCH on page 5-44.
1 Circlip 1
2 Washer 1
3 Shift shaft 1
4 Collar 1
5 Shift shaft spring 1
6 Washer 1
7 Stopper screw 1
8 Stopper lever 1
9 Washer 1
10 Oil seal 1
11 Bearing 1
12 Bearing 1
13 Stopper lever spring 1
For installation, reverse the removal proce-
dure. 
						

							SHIFT SHAFT
5-55
EAS4C81008
REMOVING THE SHIFT SHAFT
1. Remove:
 Clutch assembly
Refer to CLUTCH on page 5-44
2. Remove:
 Shift arm
 Shift rod
Refer to ENGINE REMOVAL on page 5-1
3. Remove:
 Circlip “1”
 Washer “2”
(left side of the engine)
4. Remove
 Shift shaft “1”
 Shift shaft spring “2”
Collar
 Washer
5. Remove:
 Stopper lever spring “1”
 Stopper screw “2”
 Stopper lever “3”
 Washer
EAS25420
CHECKING THE SHIFT SHAFT
1. Check:
 Shift shaft “1”
Bends/damage/wear → Replace.
 Shift lever spring “2”
 Collar “3”
Damage/wear → Replace.
EAS25430
CHECKING THE STOPPER LEVER
1. Check:
 Stopper lever “1”
Bends/damage → Replace.
Roller turns roughly → Replace the stopper 
lever.
EAS25450
INSTALLING THE SHIFT SHAFT
1. Install:
Washer
 Stopper lever “1”
 Stopper screw “2”
Stopper screw
22 Nm (2.2 m·kg, 16 ft·lb)
LOCTITE® 
						

							SHIFT SHAFT
5-56
 Stopper lever spring “3”
2. Install:
 Washer
Collar
 Shift shaft spring “1”
 Shift shaft “2”
NOTE:
 Mesh the stopper lever with the shift drum 
segment assembly.
 Lubricate the oil seal lips with lithium soap 
base grease.
 Install the end of the shift shaft spring onto 
the shift shaft spring stopper.
3. Install:
 Washer “1”
 Circlip “2” 4. Install:
 Shift rod
 Shift arm
Refer to ENGINE REMOVAL on page 5-
1.
5. Install:
 Clutch assembly
Refer to CLUTCH on page 5-44.
New 
						

							OIL PUMP
5-57
EAS24920
OIL PUMP
Removing the oil pan and oil pump
Order Job/Parts to remove Q’ty Remarks
Side cowlings  Refer to GENERAL CHASSIS on page 4-1.
Lower cowlings Refer to GENERAL CHASSIS on page 4-1.
Engine oilDrain.
Refer to CHANGING THE ENGINE OIL on 
page 3-11.
EXUP cables Refer to ENGINE REMOVAL on page 5-1
O
2 sensor
Refer to ENGINE REMOVAL on page 5-1
Muffler Refer to ENGINE REMOVAL on page 5-1
Exhaust pipe assembly Refer to ENGINE REMOVAL on page 5-1
Clutch assembly Refer to CLUTCH on page 5-44.
Water pump inlet pipe Refer to OIL COOLER on page 6-4.
Water pump outlet pipe Refer to OIL COOLER on page 6-4.
1 Oil level switch lead coupler 1 Disconnect.
2 Oil level switch 1
3 Oil level switch lead holder 1
4Oil pan 1
5 Oil pan gasket 1
6Dowel pin 1
7Drain pipe 2 
						

							OIL PUMP
5-58
8 Oil strainer 1
9 Oil pipe 1
10 Oil delivery pipe 1
11 Relief valve assembly 1
12 Oil/water pump assembly drive chain guide 1
13 Collar 1
14 Oil/water pump assembly drive sprocket 1
15 Washer 1
16 Oil/water pump assembly drive chain 1
17 Dowel pin 1
18 Oil/water pump assembly 1
For installation, reverse the removal proce-
dure.
Removing the oil pan and oil pump
Order Job/Parts to remove Q’ty Remarks 
						

							OIL PUMP
5-59
Disassembling the oil pump
Order Job/Parts to remove Q’ty Remarks
1 Oil/water pump driven sprocket 1
2 Collar 1
3 Oil pump housing 1
4 Bearing 1
5Pin 2
6 Oil pump outer rotor 1
7 Oil pump inner rotor 1
8Pin 1
For assembly, reverse the disassembly pro-
cedure. 
						

							OIL PUMP
5-60
EAS24930
REMOVING THE OIL PAN
1. Remove:
 Oil level switch “1”
 Oil pan “2”
Gasket
 Dowel pins
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.
EAS4C81012
CHECKING THE SPROCKET AND CHAIN
1. Check:
 Oil/water pump assembly drive sprocket “1”
Cracks/damage/wear → Replace the 
defective part(-s).
2. Check:
 Oil/water pump assembly drive chain “1”
Damage/stiffness → Replace the oil/water 
pump assembly drive chain and oil/water 
pump assembly drive sprocket as a set.
EAS24960
CHECKING THE OIL PUMP
1. Check:
 Oil pump driven gear “1”
 Oil pump housing “2”
Cracks/damage/wear → Replace the 
defective part(-s).
2. Measure:
 Inner-rotor-to-outer-rotor-tip clearance “a”
 Outer-rotor-to-oil-pump-housing clearance 
“b”
 Oil-pump-housing-to-inner-rotor-and-outer-
rotor clearance “c”
Out of specification → Replace the oil 
pump.
Inner-rotor-to-outer-rotor-tip
clearance
0.010–0.100 mm (0.0004–
0.0039 in)
Limit
0.180 mm (0.0071 in)
Outer-rotor-to-oil-pump-hous-
ing clearance
0.090–0.190 mm (0.0035–
0.0074 in)
Limit
0.220 mm (0.0087 in)
Oil-pump-housing-to-inner-and-
outer-rotor clearance
0.06–0.13 mm (0.0024–0.0051
in)
Limit
0.200 mm (0.0079 in)