YAMAHA YZF-R7 1999 Owners Manual

3 - 62
CHK
ADJ
REPLACING THE HEADLIGHT BULBS
EB305051
REPLACING THE HEADLIGHT BULBS
The following procedure applies to both of
the headlight bulbs.
1. Disconnect:
• headlight coupler 1
1
1

2. Remove:
• headlight bulb 1
WARNINGWARNING
Since the headlight bulb gets extremely
hot, keep flammable products and your
hands away from the bulb until it has
cooled down.
1
1

3. Install:
• headlight bulb
Secure the new headlight bulb with
the headlight bulb holder.
ACHTUNG:CAUTION:
Avoid touching the glass part of the
headlight bulb to keep it free from oil,
otherwise the transparency of the glass,
the life of the bulb and the luminous
flux will be adversely affected. If the
headlight bulb gets soiled, thoroughly
clean it with a cloth moistened with
alcohol or lacquer thinner.
4. Connect:
• headlight coupler
New

3 - 63
CHK
ADJ
ADJUSTING THE HEADLIGHT BEAMS
EB305061
ADJUSTING THE HEADLIGHT BEAMS
The following procedure applies to both of
the headlights.
1. Adjust:
• headlight beam (vertically)
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 adjusting screw 1 in direc-
tion a or b.
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 aHeadlight beam is raised.
Direction bHeadlight beam is low-
ered.
2. Adjust:
• headlight beam (horizontally)
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 adjusting screw 1 in direc-
tion a or b.
Left headlight
Right headlight
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 aHeadlight beam moves
to the right.
Direction bHeadlight beam moves
to the left.
Direction aHeadlight beam moves
to the left.
Direction bHeadlight beam moves
to the right.

ENG

4 - 1
ENGINE
EB400011
OVERHAULING THE ENGINE
ENGINE
T R..70 Nm (7.0 m • kg, 50 ft • Ib)
T R..10 Nm (1.0 m • kg, 7.2 ft • Ib)
T R..10 Nm (1.0 m • kg, 7.2 ft • Ib)
LTLT
1 3
2 1314
128 5 46791110
1
New

Order Job/Part Q’ty Remarks
Removing the drive sprocket
Remove the parts in the order listed.
Bottom cowling and front cowling Refer to “COWLINGS” in chapter 3.
1 Locknut 2 Loosen.
2 Shift rod 1
3 Shift arm 1
4 Starter cable 1
5 Starter knob 1
6 Clutch release cylinder 1
7 Dowel pin 2
4

ENG

4 - 2
ENGINE
T R..70 Nm (7.0 m • kg, 50 ft • Ib)
T R..10 Nm (1.0 m • kg, 7.2 ft • Ib)
T R..10 Nm (1.0 m • kg, 7.2 ft • Ib)
LTLT
1 3
2 1314
128 5 46791110
1
New

Order Job/Part Q’ty Remarks
8 Speed sensor 1
9 Drive sprocket cover 1
10 Oil seal support plate 1
11 Dowel pin 2
12 Push rod #2 1
13 Lock washer 1
14 Drive sprocket 1
For installation, reverse the removal
procedure.
4

ENG

4 - 3
ENGINE
T R..20 Nm (2.0 m • kg, 14 ft • Ib)
T R..20 Nm (2.0 m • kg, 14 ft • Ib)
T R..24 Nm (2.4 m • kg, 17 ft • Ib)
T R..10 Nm (1.0 m • kg, 7.2 ft • Ib)
T R..20 Nm (2.0 m • kg, 14 ft • Ib)
1
2
25654
3(8)
7New
T R..38 Nm (3.8 m • kg, 27 ft • Ib)
T R..28 Nm (2.8 m • kg, 20 ft • Ib)

Order Job/Part Q’ty Remarks
Removing the exhaust assembly
Remove the parts in the order listed.
Rear cowling Refer to “COWLINGS” in chapter 3.
Coolant Drain.
Refer to “CHANGING THE COOLANT”
in chapter 3.
Radiator assembly Refer to “RADIATOR AND THERMO-
STAT” in chapter 5.
1 Muffler 1
2 Spring 4
3 Exhaust pipe assembly 1
4 Exhaust pipe joint 1 1
5 Exhaust pipe joint 2 2
6 Exhaust pipe joint 4 1
7 Exhaust pipe joint gasket 4
For installation, reverse the removal
procedure.

ENG

4 - 4
ENGINE
Order Job/Part Q’ty Remarks
Disconnecting the leads and hoses
Disconnect the parts in the order listed.
Fuel tank and air filter case cover Refer to “FUEL TANK AND AIR FILTER
COVER” in chapter 3.
Air filter case and throttle body
assemblyRefer to “ELECTRONIC FUEL INJEC-
TION” in chapter 6.
Engine oil and oil filter cartridge Drain.
Refer to “CHANGING THE ENGINE
OIL” in chapter 3.
Oil cooler and thermostat assembly Refer to “OIL COOLER” and “THER-
MOSTAT ASSEMBLY” in chapter 5.
1 Battery negative lead 1
2 Battery positive lead 1
ACHTUNG:CAUTION:
First, disconnect the negative lead,
then the positive lead.

ENG

4 - 5
ENGINE
Order Job/Part Q’ty Remarks
3 Crankcase breather hose 1
4 Ignition coil 4
5 Camshaft sensor 1
6 Starter motor lead 1 Disconnect.
7 Ground lead 1 Disconnect.
8 Starter motor 1
9 Pickup coil coupler 1 Disconnect.
10 Plastic clip 1
11 Stator coil assembly coupler 1 Disconnect.
12 Sidestand switch coupler 1
13 Oil level switch connector 1 Disconnect.
14 Neutral switch 1
For connecting, reverse the disconnec-
tion procedure.

ENG

4 - 6
ENGINE
Order Job/Part Q’ty Remarks
Removing the engine
Remove the parts in the order listed.
1 Pinch bolt 2 Loosen.
2 Right front mounting bolt 2
3 Left front mounting bolt 2
4 Washer 2
5 Self-locking nut 2
6 Spacer bolt 2 Loosen.
7 Rear mounting bolt 2
8 Spacer 2
9 Mounting bracket 1
For installation, reverse the removal
procedure.
NOTE:
Place a suitable stand under the frame
and engine.

4 - 7
ENG

ENGINE
EB400700
INSTALLING THE ENGINE
1. Install:
• mounting bracket
1

• spacers
2

• rear mounting bolts
3

• washers
4

• left front mounting bolts
5

• right front mounting bolts
6

NOTE:

Do not fully tighten the bolts.
2. Tighten:
• spacer bolts
7

• self-locking nut
8

• left front mounting bolts
• right front mounting bolt
• pinch bolts
9

NOTE:

• Tighten the spacer bolt
7
it to specifi-
cation with a pivot shaft wrench.
• When tightened, the spacer bolt
should be flat against the engine sur-
face.
Pivot shaft wrench
90890-01471
T R..18 Nm (1.8 m · kg, 13 ft · lb)
T R..55 Nm (5.5 m · kg, 40 ft · lb)
T R..40 Nm (4.0 m · kg, 29 ft · lb)
T R..40 Nm (4.0 m · kg, 29 ft · lb)
T R..17 Nm (1.7 m · kg, 12 ft · lb)

3. Install:
• shift arm
1
NOTE:

Align the punch mark
a
in the shift shaft
with the slot in the shift arm.
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)

ENG

4 - 8
CAMSHAFTS
EB401000
CAMSHAFTS
Order Job/Part Q’ty Remarks
Removing the cylinder head cover
Remove the parts in the order listed.
Carburetor assembly Refer to “CARBURETORS” in chapter 6.
Radiator assembly and thermostat
assemblyRefer to “RADIATOR AND THERMO-
STAT” and “THERMOSTAT ASSEM-
BLY” in chapter 5.
1 Spark plug 4
2 Cylinder head cover 1
3 Cylinder head cover gasket 1
4 Timing chain guide (top side) 1
For installation, reverse the removal
procedure.