YAMAHA YZF-R7 1999 Manual Online

3 - 12
CHK
ADJ
ADJUSTING THE VALVE CLEARANCE
c. Round off the original valve pad num-
ber according to the following table.
EXAMPLE:
Original valve pad number = 148 (thickness
= 1.48 mm)
Rounded value = 150
d. Locate the rounded number of the
original valve pad and the measured
valve clearance in the valve pad
selection table. The point where the
column and row intersect is the new
valve pad number.
NOTE:
The new valve pad number is only an
approximation. The valve clearance
must be measured again and the above
steps should be repeated if the measure-
ment is still incorrect.
e. Install the new valve pad 1 and the
valve lifter 2.
NOTE:
• Lubricate the valve pad with molybde-
num disulfide grease.
• Lubricate the valve lifter with molyb-
denum disulfide oil.
• The valve lifter must turn smoothly
when rotated by hand.
• Install the valve lifter and the valve pad
in the correct place.
f. Install the exhaust and intake cam-
shafts, timing chain and camshaft
caps.
NOTE:
• Refer to “CAMSHAFTS” in chapter 4.
• Lubricate the camshaft lobes and cam-
shaft journals.
• First, install the exhaust camshaft.
• Align the camshaft marks with the
camshaft cap marks.
• Turn the crankshaft counterclockwise
several full turns to seat the parts.Last digit Rounded value
0 or 2 0
55
810
T R..
Camshaft cap bolt
10 Nm (1.0 m • kg, 7.2 ft • lb)

3 - 13
CHK
ADJ
ADJUSTING THE VALVE CLEARANCE
VALVE PAD SELECTION TABLE
INTAKE
õ MEASURED
VALVE CLEARANCE ORIGINAL VALVE PAD NUMBER
120 125 130 135 140 145
150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.00 ~ 0.01 120 125
130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220
0.02 ~ 0.07 120 125 130
135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225
0.08 ~ 0.13 120 125 130 135
140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230
0.14 ~ 0.19 120 125 130 135 140
145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235
0.20 ~ 0.25
‚ STANDARD CLEARANCE
0.26 ~ 0.31 125 130 135 140 145 150
155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.32 ~ 0.37130135140145150155160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.38 ~ 0.43 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.44 ~ 0.49 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.50 ~ 0.55 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.56 ~ 0.61 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.62 ~ 0.67 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.68 ~ 0.73 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.74 ~ 0.79 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.80 ~ 0.85 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.86 ~ 0.91 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.92 ~ 0.97 180 185 190 195 200 205 210 215 220 225 230 235 240
0.98 ~ 1.03 185 190 195 200 205 210 215 220 225 230 235 240
Example:
Valve Clearance (cold)
0.20 ~ 0.25 mm (0.008 ~ 0.010 in)
Rounded value 150
Measured valve clearance is 0.35 mm
(0.014 in)
Replace pad 150 with pad 160
Pad No. 150 = 1.50 mm (0.060 in)
Pad No. 160 = 1.60 mm (0.062 in)
Always install the valve pad with the
number facing down.1.04 ~ 1.09 190 195 200 205 210 215 220 225 230 235 240
1.10 ~ 1.15 195 200 205 210 215 220 225 230 235 240
1.16 ~ 1.21 200 205 210 215 220 225 230 235 240
1.22 ~ 1.27 205 210 215 220 225 230 235 240
1.28 ~ 1.33 210 215 220 225 230 235 240
1.34 ~ 1.39 215 220 225 230 235 240
1.40 ~ 1.45 220 225 230 235 240
1.46 ~ 1.51 225 230 235 240
1.52 ~ 1.57 230 235 240
1.58 ~ 1.63 235 240
1.64 ~ 1.69 240
EXHAUST
õ MEASURED
VALVE CLEARANCE ORIGINAL VALVE PAD NUMBER
120 125 130 135 140 145 150 155 160 165 170
175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.00 ~ 0.01 120 125 130 135 140 145
150 155 160 165 170 175 180 185 190 195 200 205 210 215
0.01 ~ 0.06 120 125 130 135 140 145 150
155 160 165 170 175 180 185 190 195 200 205 210 215 220
0.07 ~ 0.12 120 125 130 135 140 145 150 155
160 165 170 175 180 185 190 195 200 205 210 215 220 225
0.13 ~ 0.18 120 125 130 135 140 145 150 155 160
165 170 175 180 185 190 195 200 205 210 215 220 225 230
0.19 ~ 0.24 120 125 130 135 140 145 150 155 160 165
170 175 180 185 190 195 200 205 210 215 220 225 230 235
0.25 ~ 0.30
‚ STANDARD CLEARANCE
0.31 ~ 0.36 125 130 135 140 145 150 155 160 165 170 175
180 185 190 195 200 205 210 215 220 225 230 235 240
0.37 ~ 0.42130135140145150155160165170175180185 190 195 200 205 210 215 220 225 230 235 240
0.43 ~ 0.48 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.49 ~ 0.54 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.55 ~ 0.60 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.61 ~ 0.66 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.67 ~ 0.72 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.73 ~ 0.78 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.79 ~ 0.84 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.85 ~ 0.90 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.91 ~ 0.96 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.97 ~ 1.02 180 185 190 195 200 205 210 215 220 225 230 235 240
1.03 ~ 1.08 185 190 195 200 205 210 215 220 225 230 235 240
Example:
Valve Clearance (cold)
0.25 ~ 0.30 mm (0.010 ~ 0.012 in)
Rounded value 175
Measured valve clearance is
0.40 mm (0.016 in)
Replace pad 175 with pad 185
Pad No. 175 = 1.75 mm (0.069 in)
Pad No. 185 = 1.85 mm (0.073 in)
Always install the valve pad with the
number facing down.1.09 ~ 1.14 190 195 200 205 210 215 220 225 230 235 240
1.15 ~ 1.20 195 200 205 210 215 220 225 230 235 240
1.21 ~ 1.26 200 205 210 215 220 225 230 235 240
1.27 ~ 1.32 205 210 215 220 225 230 235 240
1.33 ~ 1.38 210 215 220 225 230 235 240
1.39 ~ 1.44 215 220 225 230 235 240
1.45 ~ 1.50 220 225 230 235 240
1.51 ~ 1.56 225 230 235 240
1.57 ~ 1.62 230 235 240
1.63 ~ 1.68 235 240
1.69 ~ 1.74 240

3 - 14
CHK
ADJADJUSTING THE VALVE CLEARANCE/
SYNCHRONIZING THE THROTTLE BODIES
g. Measure the valve clearance again.
h. If the valve clearance is still out of
specification, repeat all of the valve
clearance adjustment steps until the
specified clearance is obtained.
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
8. Install:
• all removed parts
NOTE:
For installation, reverse the removal
procedure. Note the following points.
SYNCHRONIZING THE THROTTLE BODIES
NOTE:
Prior to synchronizing the throttle
bodies, the valve clearance and the
engine idling speed should be properly
adjusted and the ignition timing should
be checked.
1. Stand the motorcycle on a level surface.
NOTE:
Place the motorcycle on a suitable
stand.
2. Remove:
• fuel tank
Refer to “FUEL TANK AND AIR FIL-
TER”.
• bottom cowling
• front cowling
Refer to “COWLINGS”.
3. Remove:
• bolts 1
• copper washers
11

3 - 15
CHK
ADJ
SYNCHRONIZING THE THROTTLE BODIES
4. Install:
• vacuum gauge attachments
(into the bolt holes)
• vacuum gauge
(onto the vacuum gauge attachments)
• engine tachometer
(onto the ignition coil of cylinder #1)
NOTE:
Disconnect the ignition coil coupler and
remove the ignition coil 1 of cylinder
#1, remove the rubber cover 2, and
wrap the engine tachometer lead sev-
eral times around section a of the igni-
tion coil. Then, install the ignition coil
and connect the ignition coil coupler.
5. Install:
• fuel tank
Refer to “FUEL TANK AND AIR FIL-
TER”.
6. Start the engine and let it warm up for
several minutes.
Vacuum gauge
90890-03094
Vacuum gauge attachment
90890-03060
Engine tachometer
90890-06760
1 1
2
2
a
a
7. Measure:
• engine idling speed
Out of specification ® Adjust.
Refer to “ADJUSTING THE ENGINE
IDLING SPEED”.
Engine idling speed
1,000 ~ 1,200 r/min
8. Adjust:
• throttle body synchronization
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. Turn the air screws 1 to adjust the
vacuum pressure of all throttle bodies
to specification.
NOTE:
Do not turn the synchronizing screws.1 11 1

3 - 16
CHK
ADJSYNCHRONIZING THE THROTTLE BODIES/
ADJUSTING THE ENGINE IDLING SPEED
NOTE:
The difference in vacuum pressure
between two throttle bodies should not
exceed 1.33 kPa (10 mm Hg, 0.4 in Hg).
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
9. Measure:
• engine idling speed
Out of specification ® Adjust.
10.Stop the engine and remove the mea-
suring equipment.
11.Adjust:
• throttle cable free play
Refer to “ADJUSTING THE THROTTLE
CABLE FREE PLAY”.
Vacuum pressure at engine
idling speed
15.8 ~ 18.4 kPa (120 ~ 140
mm Hg, 4.72 ~ 5.51 in Hg)
Throttle cable free play
(at the flange of the throttle
grip)
3 ~ 5 mm (0.12 ~ 0.20 in)
ADJUSTING THE ENGINE IDLING SPEED
NOTE:
Prior to adjusting the engine idling
speed, the throttle body synchronization
should be adjusted properly, the air filter
element should be clean, and the engine
should have adequate compression.
1. Start the engine and let it warm up for
several minutes.
2. Remove:
• bottom cowling
• front cowling
Refer to “COWLINGS”.

3 - 17
CHK
ADJADJUSTING THE ENGINE IDLING SPEED/
ADJUSTING THE THROTTLE CABLE FREE PLAY
3. Install:
• engine tachometer
(onto the ignition coil of cylinder #1)
NOTE:
Refer to “SYNCHRONIZING THE THROT-
TLE BODIES” for the engine tachometer
installation.
4. Measure:
• engine idling speed
Out of specification ® Adjust.
Engine tachometer
90890-06760
Engine idling speed
1,000 ~ 1,200 r/min
5. Adjust:
• engine idling speed
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. Turn the throttle stop screw 1 in
direction a or b until the specified
engine idling speed is obtained.
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
6. Adjust:
• throttle cable free play
Refer to “ADJUSTING THE THROTTLE
CABLE FREE PLAY”. Direction aEngine idling speed is
increased.
Direction bEngine idling speed is
decreased.
Throttle cable free play
(at the flange of the throttle
grip)
3 ~ 5 mm (0.12 ~ 0.20 in)
a a b b
1
1
EB303031
ADJUSTING THE THROTTLE CABLE FREE
PLAY
NOTE:
Prior to adjusting the throttle cable free
play, the engine idling speed and throt-
tle body synchronization should be
adjusted properly.

3 - 18
CHK
ADJ
ADJUSTING THE THROTTLE CABLE FREE PLAY
1. Measure:
• throttle cable free play a
Out of specification ® Adjust.
Throttle cable free play
(at the flange of the throttle
grip)
3 ~ 5 mm (0.12 ~ 0.20 in)
2. Remove:
• fuel tank
• air filter case cover
Refer to “FUEL TANK AND AIR FIL-
TER”.
• air filter case
Refer to “ELECTRONIC FUEL INJEC-
TION” in chapter 6.
3. Adjust:
• throttle cable free play
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
NOTE:
When the throttle is opened, the acceler-
ator cable 1 is pulled.
Throttle body side
a. Loosen the locknut 2 on the accelera-
tor cable.
b. Turn the adjusting bolt 3 in direction
a or b until the specified throttle
cable free play is obtained.
c. Tighten the locknut.
NOTE:
If the specified throttle cable free play
cannot be obtained on the throttle body
side of the cable, use the adjusting nut
on the handlebar side.Direction aThrottle cable free play
is increased.
Direction bThrottle cable free play
is decreased.
3 3
2 2
11
a a
b b

3 - 19
CHK
ADJADJUSTING THE THROTTLE CABLE FREE PLAY/
CHECKING THE SPARK PLUGS
Handlebar side
a. Loosen the locknut 4.
b. Turn the adjusting nut 5 in direction
c or d until the specified throttle
cable free play is obtained.
c. Tighten the locknut.
WARNINGWARNING
After adjusting the throttle cable free
play, start the engine and turn the han-
dlebars to the right and to the left to
ensure that this does not cause the
engine idling speed to change.
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
Direction cThrottle cable free play
is increased.
Direction dThrottle cable free play
is decreased.
C C
d d
7
7
5
57
7
4
4
EB303040
CHECKING THE SPARK PLUGS
The following procedure applies to all of
the spark plugs.
1. Remove:
• fuel tank
• air filter case cover
Refer to “FUEL TANK AND AIR FIL-
TER”.
• air filter case
Refer to “ELECTRONIC FUEL INJEC-
TION” in chapter 6.
2. Disconnect:
• ignition coil couplers
3. Remove:
• ignition coils
• spark plug
ACHTUNG:CAUTION:
Before removing the spark plugs, blow
away any dirt accumulated in the spark
plug wells with compressed air to pre-
vent it from falling into the cylinders.
4. Check:
• spark plug type
Incorrect ® Change.
Spark plugs
Model (manufacturer)
R0256R-10 (NGK)

3 - 20
CHK
ADJCHECKING THE SPARK PLUGS/
MEASURING THE COMPRESSION PRESSURE
5. Check:
• electrodes 1
Damage/wear ® Replace the spark
plug.
• insulator 2
Abnormal color ® Replace the spark
plug.
Normal color is medium-to-light tan.
6. Clean:
• spark plug
(with a spark plug cleaner or wire
brush)
7. Measure:
• spark plug gap a
(with a wire gauge)
Out of specification ® Regap.
8. Install:
• spark plug
NOTE:
Before installing the spark plug, clean
the spark plug and gasket surface.
Spark plug gap
0.7 ~ 0.8 mm (0.028 ~ 0.031 in)
T R..13 Nm (1.3 m · kg, 9.4 ft · lb)
EB303060
MEASURING THE COMPRESSION
PRESSURE
The following procedure applies to all of
the cylinders.
NOTE:
Insufficient compression pressure will
result in a loss of performance.
1. Measure:
• valve clearance
Out of specification ® Adjust.
Refer to “ADJUSTING THE VALVE
CLEARANCE”.
2. Start the engine, warm it up for several
minutes, and then stop it.

3 - 21
CHK
ADJ
MEASURING THE COMPRESSION PRESSURE
3. Remove:
• fuel tank
• air filter case cover
Refer to “FUEL TANK AND AIR FIL-
TER”.
• air filter case
• throttle body assembly
Refer to “ELECTRONIC FUEL INJEC-
TION” in chapter 6.
• ignition coil
4. Remove:
• spark plug
ACHTUNG:CAUTION:
Before removing the spark plugs, use
compressed air to blow away any dirt
accumulated in the spark plug wells to
prevent it from falling into the cylinders.
5. Install:
• compression gauge 1
• adapter 2
Compression gauge
90890-03081
Adapter
90890-04136
1
1

2

2

6. Measure:
• compression pressure
Out of specification ® Refer to steps
(c) and (d).
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. Set the main switch to “ON”.
b. With the throttle wide open, crank the
engine until the reading on the com-
pression gauge stabilizes.
Compression pressure (at sea
level)
Minimum
1,500 kPa
(15.0 kg/cm
2, 213 psi)
Standard
1,600 kPa
(16.0 kg/cm
2, 228 psi)
Maximum
1,700 kPa
(17.0 kg/cm
2, 242 psi)