YAMAHA YZF-R7 1999 Owners Manual

4 - 29
ENGVALVES AND VALVE SPRINGS
2. Measure:
• compressed spring force a
Out of specification ® Replace the
valve spring.
bInstalled length
3. Measure:
• valve spring tilt a
Out of specification ® Replace the
valve spring.
Compressed spring force
(installed)
Inner spring
Intake valve spring
10.30 ~ 11.93 kg at
27.96 mm
(22.7 ~ 26.3 lb at 1.10 in)
Exhaust valve spring
10.81 ~ 12.44 kg at
24.6 mm
(23.8 ~ 27.4 lb at 0.97 in)
Outer spring
Intake valve spring
23.45 ~ 27.12 kg at
32.03 mm
(51.7 ~ 59.8 lb at 1.26 in)
Exhaust valve spring
29.16 ~ 33.55 kg at
30.25 mm
(62.3 ~ 74.0 lb at 1.19 in)
Maximum spring tilt
Inner spring
Intake valve spring
1.4 mm (0.055 in)
Exhaust valve spring
1.3 mm (0.051 in)
Outer spring
Intake valve spring
1.6 mm (0.063 in)
Exhaust valve spring
1.5 mm (0.059 in)
EB403430
CHECKING THE VALVE LIFTERS
The following procedure applies to all of
the valve lifters.
1. Check:
• valve lifter
Damage/scratches ® Replace the
valve lifters and cylinder head.

4 - 30
ENGVALVES AND VALVE SPRINGS
EB403702
INSTALLING THE VALVES
The following procedure applies to all of
the valves and related components.
1. Deburr:
• valve stem end
(with an oil stone)
2. Lubricate:
• valve stem 1
• oil seal 2
(with the recommended lubricant)
Recommended lubricant
Molybdenum disulfide oil
3. Install:
• oil seal 1
• valve 2
• lower spring seat 3
• valve springs 4
• upper spring seat 5
(into the cylinder head)
NOTE:
• Make sure that each valve is installed
in its original place.
• Install the valve spring with the larger
pitch a facing up.
b Smaller pitch
New
aa
b
ba

4 - 31
ENG

VALVES AND VALVE SPRINGS
4. Install:
• valve cotters
1
NOTE:

Install the valve cotters by compressing
the valve spring with the valve spring
compressor
2
and attachment
3
.
5. To secure the valve cotters
1
onto the
valve stem, lightly tap the valve tip with
a soft-face hammer.
ACHTUNG:CAUTION:

Hitting the valve tip with excessive
force could damage the valve.
Valve spring compressor
90890-04019
Attachment
(for the intake valve spring)
9080-04114
(for the exhaust valve spring)
90890-04108
6. Lubricate:
• valve pad
(with the recommended lubricant)
Recommended lubricant
Molybdenum disulfide oil
7. Install:
• valve pad
• valve lifter
NOTE:

• The valve lifter must move smoothly
when rotated with a finger.
• Each valve lifter and valve pad must be
reinstalled in its original position.

ENG

4 - 32
GENERATOR
EB410000
GENERATOR
Order Job/Part Q’ty Remarks
Removing the stator coil assembly
Remove the parts in the order listed.
Bottom cowling and front cowling Refer to “COWLINGS” in chapter 3.
Engine oil Drain.
Refer to “CHANGING THE ENGINE
OIL” in chapter 3.
1 Throttle stop screw holder 1
2 Generator rotor cover 1
3 Generator rotor cover gasket 1
4 Dowel pin 2
5 Generator rotor bolt 1
6 Generator rotor 1
7 Stator coil assembly coupler 1 Disconnect.
8 Stator coil assembly lead holder 1
9 Stator coil assembly 1
For installation, reverse the removal
procedure.

4 - 33
ENG

GENERATOR
EB410110
REMOVING THE GENERATOR
1. Remove:
• generator rotor cover
1

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.
1
1

2. Remove:
• generator rotor bolt
1

• washer
NOTE:

While holding the generator rotor
2
with the rotor holding tool
3
, loosen the
generator rotor bolt.
Rotor holding tool
90890-01235
3. Remove:
• generator rotor
1
(with the flywheel puller
2
and rotor
holding tool
3
)
Flywheel puller
90890-01080
EB410700
INSTALLING THE GENERATOR
1. Apply:
• sealant
(onto the stator coil assembly lead
grommet)
2. Install:
• generator rotor
• washer
• generator rotor bolt
WARNINGWARNING

Always use a new generator rotor bolt.
ACHTUNG:CAUTION:

• Clean the tapered portion of the crank-
shaft and the generator rotor hub with
lacquer thinner.
• Lubricate the generator rotor bolt
threads with engine oil.
Yamaha bond No. 1215
90890-85505

4 - 34
ENG

GENERATOR
3. Tighten:
• generator rotor bolt
1
NOTE:

While holding the generator rotor
2
with the rotor holding tool
3
, tighten
the generator rotor bolt.
4. Install:
• generator rotor cover
NOTE:

Tighten the generator rotor cover bolts
in stages and in a crisscross pattern.
Rotor holding tool
90890-01235
New
T R..65 Nm (6.5 m · kg, 47 ft · lb)

ENG

4 - 35
PICKUP COIL
PICKUP COIL
T R..45 Nm (4.5 m • kg, 32 ft • Ib)
T R..12 Nm (1.2 m • kg, 8.7 ft • Ib)
T R..4 Nm (0.4 m • kg, 2.9 ft • Ib)
T R..15 Nm (1.5 m • kg, 11 ft • Ib)
E
LTLT
LTLT
1
(6)23
4
5 64 7
New

Order Job/Part Q’ty Remarks
Removing the pickup coil and
pickup coil rotor
Remove the parts in the order listed.
Fuel tank Refer to “FUEL TANK AND AIR FIL-
TER” in chapter 3.
Bottom cowling and front cowling Refer to “COWLINGS” in chapter 3.
Engine oil Drain.
Refer to “CHANGING THE ENGINE
OIL” in chapter 3.
Generator rotor cover Refer to “GENERATOR”.
1 Pickup coil lead holder 1
2 Pickup coil rotor cover 1
3 Pickup coil rotor cover gasket 1
4 Dowel pin 2

ENG

4 - 36
PICKUP COIL
T R..45 Nm (4.5 m • kg, 32 ft • Ib)
T R..12 Nm (1.2 m • kg, 8.7 ft • Ib)
T R..4 Nm (0.4 m • kg, 2.9 ft • Ib)
T R..15 Nm (1.5 m • kg, 11 ft • Ib)
E
LTLT
LTLT
1
(6)23
4
5 64 7
New

Order Job/Part Q’ty Remarks
5 Pickup coil coupler 1 Disconnect.
6 Pickup coil 1
7 Pickup coil rotor 1
For installation, reverse the removal
procedure.

4 - 37
ENG

PICKUP COIL
REMOVING THE PICKUP COIL ROTOR
1. Remove:
• pickup coil lead holder
1

• pickup coil rotor cover
2

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
2
1

1

2. Remove:
• pickup coil rotor bolt
1

• washer
• pickup coil rotor
2

NOTE:

While holding the generator rotor
3
with the rotor holding tool
4, loosen the
pickup coil rotor bolt.
Rotor holding tool
90890-01235
2
2

1

1

INSTALLING THE PICKUP COIL ROTOR
1. Install:
• pickup coil rotor 1
• washer
• pickup coil rotor bolt
NOTE:
When installing the pickup coil rotor,
align the groove 2 in the crankshaft
sprocket with the projection a in the
pickup coil rotor.
ACHTUNG:CAUTION:
Lubricate the pickup coil rotor bolt
threads with engine oil.
1
1

2

2
a
a

4 - 38
ENGPICKUP COIL
2. Tighten:
• pickup coil rotor bolt 1
NOTE:
While holding the generator rotor 2
with the rotor holding tool 3, tighten
the pickup coil rotor bolt.
Rotor holding tool
90890-01235
1
1

T R..45 Nm (4.5 m · kg, 32 ft · lb)
3. Apply:
• sealant
(onto the pickup coil lead grommet)
Yamaha bond No. 1215
90890-85505
4. Install:
• pickup coil rotor cover
• pickup coil lead holder
• clutch cable holder
NOTE:
• When installing the pickup coil rotor
cover, align the timing chain guide
(intake side) pin 1 of the with the hole
2 in the pickup coil rotor cover.
• Tighten the pickup coil rotor cover
bolts in stages and in a crisscross pat-
tern.
2
2
1

1