YAMAHA YZF-R7 1999 Owner's Guide

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TROUBLESHOOTING CHART
5. Engine overheatingEW000070
WARNING
Do not remove the radiator cap when the engine and radiator are hot. Scalding hot fluid and steam may be blown out
under pressure, which could cause serious injury. Open the radiator cap as follows. Wait until the engine has
cooled. Remove the radiator cap stopper by removing the screw. Place a thick rag like a towel over the radiator cap
and slowly rotate the cap counterclockwise to the detent. This procedure allows any residual pressure to escape.
When the hissing sound has stopped, press down on the cap while turning counterclockwise and remove it.
NOTE:
If it is difficult to get the recommended coolant, tap water can be temporarily used, provided that it is changed to the recom-
mended coolant as soon as possible.
Wait until the
engine has cooled.Check the coolant level in the
reservoir tank and/or radiator.
Level is OK.
Level is low, check the
cooling system for leakage.
No
leakage.
Leakage.Ask a Yamaha dealer to inspect
and repair the cooling system.
Add coolant. (See NOTE.)
Restart the engine. If the engine overheats again, ask a
Yamaha dealer to inspect and repair the cooling system.

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IMPORTANT INFORMATION
EB102000
IMPORTANT INFORMATION
PREPARATION FOR REMOVAL AND
DISASSEMBLY
1. Before removal and disassembly,
remove all dirt, mud, dust, and foreign
material.
2. Use only the proper tools and cleaning
equipment.
Refer to “SPECIAL TOOLS”.
3. When disassembling, always keep
mated parts together. This includes
gears, cylinders, pistons and other parts
that have been “mated” through normal
wear. Mated parts must always be
reused or replaced as an assembly.
4. During disassembly, clean all of the
parts and place them in trays in the
order of disassembly. This will speed up
assembly and allow for the correct
installation of all parts.
5. Keep all parts away from any source of
fire.
EB102010
REPLACEMENT PARTS
Use only genuine Yamaha parts for all
replacements. Use oil and grease recom-
mended by Yamaha for all lubrication jobs.
Other brands may be similar in function
and appearance, but inferior in quality.
EB102020
GASKETS, OIL SEALS AND O-RINGS
1. When overhauling the engine, replace
all gaskets, seals, and O-rings. All gasket
surfaces, oil seal lips, and O-rings must
be cleaned.
2. During reassembly, properly oil all mat-
ing parts and bearings and lubricate the
oil seal lips with grease.

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IMPORTANT INFORMATION
USING A DYNAMOMETER
The YZF-R7 has a carbon muffler that may
change color when exposed to high tem-
peratures. Therefore, when using a dyna-
mometer always use a fan to cool the
muffler.
EB102030
LOCK WASHERS/PLATES AND COTTER
PINS
After removal, replace all lock washers/
plates
1
and cotter pins. After the bolt or
nut has been tightened to specification,
bend the lock washer tabs and the cotter
pin ends along a flat of the bolt or nut.
EB102040
BEARINGS AND OIL SEALS
1. Install bearings and oil seals so that the
manufacturer’s marks or numbers are
visible. When installing oil seals, lubri-
cate the oil seal lips with a light coat of
lithium soap base grease. Oil bearings
liberally when installing, if appropriate.
1
Oil seal
ACHTUNG:CAUTION:

Do not spin the bearing with compressed
air because this will damage the bearing
surfaces.
1
Bearing
EB102050
CIRCLIPS
Before reassembly, check all circlips care-
fully and replace damaged or distorted cir-
clips. Always replace piston pin clips after
one use. When installing a circlip
1
, make
sure that the sharp-edged corner
2
is posi-
tioned opposite the thrust
3
that the circlip
receives.
4
Shaft

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CHECKING THE CONNECTIONS
EB103000
CHECKING THE CONNECTIONS
Check the leads, couplers, and connectors
for stains, rust, moisture, etc.
1. Disconnect:
• lead
• coupler
• connector
2. Check:
• lead
• coupler
• connector
Moisture
®
Dry with an air blower.
Rust/stains
®
Connect and disconnect
several times.
3. Check:
• all connections
Loose connection
®
Connect properly.
NOTE:

If the pin
1
on the terminal is flattened,
bend it up.
4. Connect:
• lead
• coupler
• connector
NOTE:

Make sure that all connections are tight.
5. Check:
• continuity
(with the pocket tester)
NOTE:

• If there is no continuity, clean the termi-
nals.
• When checking the wire harness, perform
steps (1) to (3).
• As a quick remedy, use a contact revital-
izer available at most part stores.
Pocket tester
90890-03112

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SPECIAL TOOLS
EB104000
SPECIAL TOOLS
The following special tools are necessary for complete and accurate tune-up and assembly.
Use only the appropriate special tools as this will help prevent damage caused by the use of
inappropriate tools or improvised techniques.
When placing an order, refer to the list provided below to avoid any mistakes.
Tool No. Tool name/Function Illustration
90890-01080Flywheel puller
This tool is used to remove the generator
rotor.
90890-01235Rotor holding tool
This tool is used to hold the generator
rotor when removing or installing the gen-
erator rotor bolt or pickup coil rotor bolt.
90890-01286Drive chain cutter
This tool is used to remove the drive
chain.
90890-01304Piston pin puller
This tool is used to remove the piston
pins.
Radiator cap
tester
90890-01325
Adapter
90890-01352Radiator cap tester
Adapter
These tools are used to check the cooling
system.
90890-01403Steering nut wrench
This tool is used to loosen or tighten the
steering stem ring nuts.
90890-01426Oil filter wrench
This tool is needed to loosen or tighten
the oil filter cartridge.
90890-01434Rod holder
This tool is used to support the damper
adjusting rod.

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SPECIAL TOOLS
Rod puller
90890-01437
Rod puller
attachment
90890-01436Rod puller
Rod puller attachment
These tools are used to pull up the front
fork damper rod.
90890-01441Fork spring compressor
This tool is used to disassemble or assem-
ble the front fork legs.
90890-01442Fork seal driver
This tool is used to install the front fork’s
oil seal and dust seal.
90890-01471Pivot shaft wrench
This tool is used to remove or install the
engine mounting spacer bolts.
90890-01472Front fork cap bolt wrench
This tool is used to remove or install the
front fork cap bolt.
90890-01473Damper rod holder
This tool is used to hold the damper rod
assembly when loosening or tightening
the damper rod assembly bolt.
90890-03008Micrometer (50 ~ 75 mm)
This tool is used to measure the piston
skirt diameter.
90890-03017Cylinder bore gauge (50 ~ 100 mm)
This tool is used to measure the cylinder
bore.
Vacuum gauge
90890-03094
Vacuum gauge
attachment
90890-03060Vacuum gauge
Vacuum gauge attachment
This gauge is used to synchronize the
throttle bodies.
Tool No. Tool name/Function Illustration

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SPECIAL TOOLS
Compression
gauge
90890-03081
Adapter
90890-04136Compression gauge
Adapter
These tools are used to measure engine
compression.
90890-03112Pocket tester
This tool is used to check the electrical
system.
Pressure
gauge
90890-03153
Adapter
90890-03151Pressure gauge
Adapter
These tools are used to measure the fuel
pressure.
90890-03149Test coupler adapter
This tool is used to check the electrical
control system.
90890-03171Co, diagnosis switch box
This tool is used to check the electrical
control system.
Valve spring com-
pressor
90890-04019
Attachment
90890-04108
90890-04114
Valve spring compressor
Attachment
These tools are used to remove or install
the valve assemblies.
Middle driven shaft
bearing driver
90890-04058
Mechanical seal
installer
90890-04078
Middle driven shaft bearing driver
Mechanical seal installer
These tools are used to install the water
pump seal.
90890-04086Clutch holding tool
This tool is used to hold the clutch boss
when removing or installing the clutch
boss nut.
90890-04111Valve guide remover
This tool is used to remove or install the
valve guides.
Tool No. Tool name/Function Illustration
MODEUP
YES/ON
DOWN
NO/OFF

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SPECIAL TOOLS
90890-04112Valve guide installer
This tool is used to install the valve
guides.
90890-04113Valve guide reamer
This tool is used to rebore the new valve
guides.
90890-06754Ignition checker
This tool is used to check the ignition sys-
tem components.
90890-06756Mity vac
This tool is used to measure the vacuum
pressure.
90890-06760Engine tachometer
This tool is used to check engine speed.
90890-85505Yamaha bond No. 1215
This bond is used to seal two mating sur-
faces (e.g., crankcase mating surfaces).
Tool No. Tool name/Function Illustration

GENERAL SPECIFICATIONS
SPEC

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SPECIFICATIONS
GENERAL SPECIFICATIONS
Item Standard Limit
Dimensions
Overall length 2,060 mm (81.1 in) ----
Overall width 720 mm (28.3 in) ----
Overall height 1,125 mm (44.3 in) ----
Seat height 840 mm (33.1 in) ----
Wheelbase 1,400 mm (55.1 in) ----
Minimum ground clearance 120 mm (4.72 in) ----
Minimum turning radius 3,800 mm (150 in) ----
Weight
Wet (with oil and a full fuel tank) 207 kg (456 lb) ----
Dry (without oil and fuel) 176 kg (388 lb) ----
Maximum load (total of rider and
accessories) 317 kg (699 lb) ----
2

ENGINE SPECIFICATIONS
SPEC

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ENGINE SPECIFICATIONS
Item Standard Limit
Engine
Engine type Liquid-cooled, 4-stroke, DOHC ----
Displacement 749 cm
3

----
Cylinder arrangement Forward-inclined parallel 4-cylinder ----
Bore
´
stroke 72
´
46 mm (2.83
´
1.81 in) ----
Compression ratio 11.4:1 ----
Engine idling speed 1,000 ~ 1,200 r/min ----
Vacuum pressure at engine idling
speed15.8 ~ 18.4 kPa
(120 ~ 140 mm Hg, 4.72 ~ 5.51 in Hg)----
Standard compression pressure
(at sea level) 157 kPa
(1.57 kgf/cm
2

, 22.3 psi) at 500 r/min----
Fuel
Recommended fuel Premium unleaded gasoline ----
Fuel tank capacity
Total (including reserve) 23 L (20.2 Imp qt, 24.3 US qt) ----
Reserve only 4.8 L (4.22 Imp qt, 5.07 US qt) ----
Engine oil
Lubrication system Wet sump ----
Recommended oil
Yamalube 4 (20W40) or SAE 20W40 type
SE motor oil (40˚F/5˚C or above)
(Non-Friction modified)
Yamalube 4 (10W40) or SAE 10W40 type
SE motor oil (60˚F/15˚C or below)
(Non-Friction modified)----
Quantity
Total amount 3.6 L (3.2 Imp qt, 3.8 US qt) ----
Without oil filter cartridge
replacement2.6 L (2.3 Imp qt, 2.7 US qt) ----
With oil filter cartridge replace-
ment2.8 L (2.5 Imp qt, 3.0 US qt) ----
Oil pressure (hot) 40 kPa (0.4 kgf/cm
2

, 5.69 psi) at
1,100 r/min ----
Relief valve opening pressure 480 ~ 560 kPa
(4.8 ~ 5.6 kgf/cm
2

, 68.3 ~ 79.7 psi)----
2