YAMAHA YZF-R7 1999 Owners Manual

5 - 2
COOL

RADIATOR AND THERMOSTAT
Order Job/Part Q’ty Remarks
11 Radiator outlet hose 1
12 Lower radiator guard 1
13 Lower radiator 1
14 Lower radiator breather hose 1
15 Radiator joint hose 1
16 Plastic band 1
17 Oil cooler outlet hose 1 Disconnect.
18 Radiator inlet hose 1
19 Horn 1
20 Upper radiator 1
21 Radiator fan 1
22 Upper radiator bracket 2
23 Lower radiator bracket 1
For installation, reverse the removal
procedure.
5

5 - 3
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EB502000
RADIATOR AND THERMOSTAT
Order Job/Part Q’ty Remarks
Removing the thermostat assembly
Remove the parts in the order listed.
Rider seat and fuel tank Refer to “SEATS” and “FUEL TANK” in
chapter 3.
Air filter case and rubber cover Refer to “AIR FILTER CASE AND IGNI-
TION COIL PLATE” in chapter 3.
Carburetor assembly Refer to “CARBURETORS” in chapter 6.
Coolant Drain.
Refer to “CHANGING THE COOLANT”
in chapter 3.
Fuel tank and air filter case cover Refer to “FUEL TANK AND AIR FIL-
TER” in chapter 3.
Air filter case Refer to “ELECTRONIC FUEL INJEC-
TION” in chapter 6.
1 Thermostat assembly 1
2 Thermostat assembly inlet hose 1
RADIATOR AND THERMOSTAT

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RADIATOR AND THERMOSTAT
Order Job/Part Q’ty Remarks
3 Thermostat assembly breather hose 1
4 Coolant temperature sensor 1
5 Copper washer 1
6 Plastic band 1
7 Thermostat assembly inlet pipe 1
For installation, reverse the removal
procedure.

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1
3
2
T R..10 Nm (1.0 m • kg, 7.2 ft • Ib)

RADIATOR AND THERMOSTAT
EB502010
Order Job/Part Q’ty Remarks
Disassembling the thermostat
assembly
Remove the parts in the order listed.
1
Thermostat housing cover 1
2
Thermostat 1
3
Thermostat housing 1
For assembly, reverse the disassembly
procedure.

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RADIATOR AND THERMOSTAT
EB500010
CHECKING THE RADIATOR
1. Check:
• radiator fins
Obstruction
®
Clean.
Apply compressed air to the rear of the
radiator.
Damage
®
Repair or replace.
NOTE:

Straighten any flattened fins with a thin,
flat-head screwdriver.
2. Check:
• radiator hoses
Cracks/damage
®
Replace.
3. Measure:
• radiator cap opening pressure
Below the specified pressure
®
Replace the radiator cap.
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. Install the radiator cap tester
1
and
adapter
2
onto the radiator cap
3
.
b. Apply the specified pressure for ten
seconds and make sure that there is
no drop in pressure.
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
Radiator cap opening pressure
95 ~ 125 kPa
(0.95 ~ 1.25 kg/cm
2

,
3.51 ~ 7.78 psi)
Radiator cap tester
90890-01325
Adapter
90890-01352
4. Check:
• radiator fan
Damage
®
Replace.
Malfunction
®
Check and repair.
Refer to “COOLING SYSTEM” in chap-
ter 8.

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RADIATOR AND THERMOSTAT
EB502020
CHECKING THE THERMOSTAT
1. Check:
• thermostat
1

Does not open at 71 ~ 85 ˚C (159.8 ~
185 ˚F)
®
Replace.
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. Suspend the thermostat in a con-
tainer filled with water.
b. Slowly heat the water.
c. Place a thermometer in the water.
d. While stirring the water, observe the
thermostat and thermometer’s indi-
cated temperature.
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
1
Thermostat
2
Thermometer
3
Water
4
Container

Fully closed
õ
Fully open
NOTE:

If the accuracy of the thermostat is in
doubt, replace it. A faulty thermostat
could cause serious overheating or
overcooling.
2. Check:
• thermostat housing cover
• thermostat housing
Cracks/damage
®
Replace.
EB502030
ASSEMBLING THE THERMOSTAT
ASSEMBLY
1. Install:
• thermostat housing
1

• thermostat
2

• thermostat housing cover
NOTE:

Install the thermostat with its breather
hole
a
facing up.
2
1
1
2
a a

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RADIATOR AND THERMOSTAT
INSTALLING THE THERMOSTAT
ASSEMBLY AND RADIATOR
1. Fill:
• cooling system
(with the specified amount of the rec-
ommended coolant)
Refer to “CHANGING THE COOLANT”
in chapter 3.
2. Check:
• cooling system
Leaks
®
Repair or replace any faulty
part.
3. Measure:
• radiator cap opening pressure
Below the specified pressure
®
Replace the radiator cap.
Refer to “CHECKING THE RADIATOR”.

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OIL COOLER
EB501000
OIL COOLER
Order Job/Part Q’ty Remarks
Removing the oil cooler
Remove the parts in the order listed.
Radiator assembly Refer to “RADIATOR AND THERMO-
STAT”.
Exhaust pipe assembly Refer to “ENGINE” in chapter 4.
Engine oil Drain.
Refer to “CHANGING THE ENGINE
OIL” in chapter 3.
1 Oil cooler outlet hose 1
2 Bolt 1
3 Gasket 1
4 Oil cooler 1
5 Oil cooler inlet hose 1
6 Water pump outlet pipe 1
7 Water jacket joint inlet hose 1
8 Water jacket joint 1
For installation, reverse the removal
procedure.

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OIL COOLER
EB501010
CHECKING THE OIL COOLER
1. Check:
• oil cooler
Cracks/damage
®
Replace.
2. Check:
• oil cooler inlet hose
• oil cooler outlet hose
Cracks/damage/wear
®
Replace.
3. Check:
• water jacket joint
• water jacket joint inlet hose
• water pump outlet hose
Cracks/damage
®
Replace.
EB501020
INSTALLING THE OIL COOLER
1. Clean:
• mating surfaces of the oil cooler and
the crankcase
(with a cloth dampened with lacquer
thinner)
2. Install:
• O-ring
• oil cooler
1
• gasket 2
• bolt 3
NOTE:
• Before installing the oil cooler, lubri-
cate the oil cooler bolt and O-ring with
a thin coat of engine oil.
• Make sure that the O-ring is positioned
properly.
• Align the projection a on the oil
cooler with the projection b in the
crankcase.
1
1

3

3

2

2

a ab
b
New
New
T R..63 Nm (6.3 m · kg, 45 ft · lb)

5 - 11
COOLOIL COOLER
3. Fill:
• cooling system
(with the specified amount of the rec-
ommended coolant)
Refer to “CHANGING THE COOLANT”
in chapter 3.
• crankcase
(with the specified amount of the rec-
ommended engine oil)
Refer to “CHANGING THE ENGINE
OIL” in chapter 3.
4. Check:
• cooling system
Leaks ® Repair or replace any faulty
part.
5. Measure:
• radiator cap opening pressure
Below the specified pressure ®
Replace the radiator cap.
Refer to “CHECKING THE RADIATOR”.