YAMAHA YZF-R7 1999 Service Manual

ENGINE SPECIFICATIONS
SPEC

2 - 3
Oil filter
Oil filter type Cartridge (paper) ----
Bypass valve opening pressure 180 ~ 220 kPa
(1.8 ~ 2.2 kgf/cm
2

, 25.6 ~ 31.3 psi)----
Oil pump

Oil pump type Trochoidal ----
Inner rotor-to-outer rotor tip clear-
ance0.09 ~ 0.15 mm (0.004 ~ 0.006 in) ----
Outer rotor-to-oil pump housing
clearance0.03 ~ 0.08 mm (0.001 ~ 0.003 in) ----
Cooling system
Radiator capacity 2.75 L (2.42 Imp qt, 2.91 US qt)
Radiator cap opening pressure 95 ~ 125 kPa
(0.95 ~ 1.25 kgf/cm
2

, 13.1 ~ 17.8 psi)----
Upper radiator core
Width 414 mm (16.3 in) ----
Height 248 mm (9.76 in) ----
Depth 24 mm (0.94 in) ----
Lower radiator core
Width 211 mm (8.31 in) ----
Height 158 mm (6.22 in) ----
Depth 24 mm (0.94 in) ----
Coolant reservoir
Capacity 0.6 L (0.53 Imp qt, 0.63 US qt) ----
Water pump
Water pump type Single-suction centrifugal pump ----
Reduction ratio 88/47
´
28/25 (2.097) ----
Maximum impeller shaft tilt ---- 0.15 mm
(0.006 in)
Starting system type
Electric starter
Spark plugs
Model (manufacturer)
´
quantity R0256R-10 (NGK)
´
4 ----
Spark plug gap 0.7 ~ 0.8 mm (0.028 ~ 0.031 in) ----
Cylinder head
Maximum warpage ---- 0.06 mm
(0.0024 in) Item Standard Limit

ENGINE SPECIFICATIONS
SPEC

2 - 4
Camshafts
Drive system Chain drive (right) ----
Camshaft cap inside diameter 24.500 ~ 24.521 mm
(0.9646 ~ 0.9654 in)----
Camshaft journal diameter 24.452 ~ 24.465 mm
(0.9627 ~ 0.9632 in)----
Camshaft journal-to-camshaft cap
clearance0.035 ~ 0.069 mm (0.0014 ~ 0.0027 in) ----
Intake camshaft lobe dimensions
Measurement A 33.36 ~ 33.46 mm (1.3134 ~ 1.3173 in) 33.31 mm
(1.3114 in)
Measurement B 24.95 ~ 25.05 mm (0.9823 ~ 0.9862 in) 24.90 mm
(0.9803 in)
Measurement C 8.31 ~ 8.51 mm (0.3272 ~ 0.3350 in) ----
Exhaust camshaft lobe dimen-
sions
Measurement A 33.00 ~ 33.10 mm (1.2992 ~ 1.3031 in) 32.95 mm
(1.2972 in)
Measurement B 24.986 ~ 25.086 mm
(0.9837 ~ 0.9876 in)24.936 mm
(0.9817 in)
Measurement C 7.95 ~ 8.15 mm (0.3130 ~ 0.3209 in) ----
Maximum camshaft runout ---- 0.03 mm
(0.0012 in) Item Standard Limit
C
A
B
C
A
B

ENGINE SPECIFICATIONS
SPEC

2 - 5
Timing chain
Model/number of links DID219FTH3/100 ----
Tensioning system Automatic ----
Valves, valve seats, valve guides
Valve clearance (cold)
Intake 0.20 ~ 0.25 mm (0.0079 ~ 0.0098 in) ----
Exhaust 0.25 ~ 0.30 mm (0.0098 ~ 0.0118 in) ----
Valve dimensions
Valve head diameter A
Intake 22.1 ~ 22.3 mm (0.8701 ~ 0.8780 in) ----
Exhaust 23.4 ~ 23.6 mm (0.9213 ~ 0.9291 in) ----
Valve face width B
Intake 0.54 ~ 1.57 mm (0.0213 ~ 0.0618 in) ----
Exhaust 0.88 ~ 1.87 mm (0.0346 ~ 0.0736 in) ----
Valve seat width C
Intake 0.7 ~ 0.9 mm (0.028 ~ 0.035 in) ----
Exhaust 0.7 ~ 0.9 mm (0.028 ~ 0.035 in) ----
Valve margin thickness D
Intake 0.9 ~ 1.2 mm (0.028 ~ 0.047 in) ----
Exhaust 1.0 ~ 1.3 mm (0.039 ~ 0.051 in) ----
Valve stem diameter
Intake 3.983 ~ 3.995 mm (0.1568 ~ 0.1573 in) 3.953 mm
(0.1556 in)
Exhaust 3.978 ~ 3.990 mm (0.1566 ~ 0.1571 in) 3.948 mm
(0.1544 in)
Valve guide inside diameter
Intake 4.000 ~ 4.012 mm (0.1575 ~ 0.1580 in) 4.05 mm
(0.1594 in)
Exhaust 4.000 ~ 4.012 mm (0.1575 ~ 0.1580 in) 4.05 mm
(0.1594 in)
Valve stem-to-valve guide clear-
ance
Intake 0.005 ~ 0.029 mm (0.0002 ~ 0.0011 in) 0.06 mm
(0.0024 in)
Exhaust 0.010 ~ 0.034 mm (0.0004 ~ 0.0013 in) 0.07 mm
(0.0028 in) Item Standard Limit
Head Diameter
B
Face WidthC
Seat Width
D
Margin ThicknessA

ENGINE SPECIFICATIONS
SPEC

2 - 6
Valve stem runout ---- 0.01 mm
(0.0004 in)
Valve seat width
Intake 0.9 ~ 1.1 mm (0.035 ~ 0.043 in) 1.6 mm
(0.06 in)
Exhaust 0.9 ~ 1.1 mm (0.035 ~ 0.043 in) 1.6 mm
(0.06 in)
Valve springs
Inner spring
Free length
Intake 32.35 mm (1.27 in) 30.73 mm
(1.21 in)
Exhaust 28.82 mm (1.13 in) 27.37 mm
(1.08 in)
Installed length (valve closed)
Intake 27.96 mm (1.10 in) ----
Exhaust 24.6 mm (0.97 in) ----
Compressed spring force
(installed)
Intake 101 ~ 117 N
(10.30 ~ 11.93 kgf, 22.7 ~ 26.3 lb)----
Exhaust 106 ~ 122 N
(10.81 ~ 12.44 kgf, 23.8 ~ 27.4 lb)----
Spring tilt
Intake ----2.5˚ /1.4 mm
(2.5˚/0.055 in)
Exhaust ----2.5˚ /1.3 mm
(2.5˚/0.051 in)
Winding direction (top view)
Intake Counter clockwise ----
Exhaust Counter clockwise ----Item Standard Limit

ENGINE SPECIFICATIONS
SPEC

2 - 7
Outer springs
Free length
Intake 36.42 mm (1.43 in) 34.60 mm
(1.36 in)
Exhaust 33.91 mm (1.34 in) 32.21 mm
(1.27 in)
Installed length (valve closed)
Intake 32.03 mm (1.26 in) ----
Exhaust 30.25 mm (1.19 in) ----
Compressed spring force
(installed)
Intake 230 ~ 266 N
(23.45 ~ 27.12 kgf, 51.7 ~ 59.8 lb)----
Exhaust 286 ~ 329 N
(29.16 ~ 33.55 kgf, 62.3 ~ 74.0 lb)----
Spring tilt
Intake ----2.5˚ /1.6 mm
(2.5˚/0.063 in)
Exhaust ----2.5˚ /1.5 mm
(2.5˚/0.059 in)
Winding direction (top view)
Intake Clockwise ----
Exhaust Clockwise ----
Cylinders
Cylinder arrangement Forward-inclined, parallel 4-cylinder ----
Bore

´

stroke 72
´
46 mm (2.83
´
1.81 in) ----
Compression ratio 11.4:1 ----
Bore 72.000 ~ 72.008 mm
(2.8346 ~ 2.8350 in)----
Maximum taper ---- 0.05 mm
(0.0016 in)
Maximum out of round ---- 0.05 mm
(0.0016 in) Item Standard Limit

ENGINE SPECIFICATIONS
SPEC

2 - 8
Pistons
Piston-to-cylinder clearance 0.028 ~ 0.054 mm (0.0011 ~ 0.0021 in) 0.1 mm
(0.004 in)
Diameter D 71.954 ~ 71.972 mm
(2.8328 ~ 2.8335 in)----
Height H 10 mm (0.39 in) ----
Piston pin bore (in the piston)
Diameter 17.004 ~ 17.015 mm
(0.6694 ~ 0.6699 in)17.045 mm
(0.6711 in)
Offset 0 mm (0 in) ----
Piston pins
Outside diameter 16.995 ~ 17.000 mm
(0.6691 ~ 0.6693 in)16.975 mm
(0.6683 in)
Piston pin-to-piston pin bore
clearance0.004 ~ 0.020 mm
(0.00016 ~ 0.00079 in)0.070 mm
(0.0028 in)
Piston rings
Top ring

Ring type Barrel ----
Dimensions (B

´

T) 0.8
´
2.7 mm (0.031
´
0.106 in) ----
End gap (installed) 0.15 ~ 0.25 mm (0.006 ~ 0.010 in) 0.50 mm
(0.020 in)
Ring side clearance 0.03 ~ 0.07 mm (0.0012 ~ 0.0028 in) 0.12 mm
(0.0047 in)
2nd ring
Ring type Taper ----
Dimensions (B

´

T) 0.8
´
2.8 mm (0.031
´
0.110 in) ----
End gap (installed) 0.25 ~ 0.35 mm (0.009 ~ 0.014 in) 0.70 mm
(0.028 in)
Ring side clearance 0.02 ~ 0.06 mm (0.0008 ~ 0.0024 in) 0.12 mm
(0.0047 in) Item Standard Limit
H
D
T
B
B
T

ENGINE SPECIFICATIONS
SPEC

2 - 9
Oil ring
Dimensions (B

´

T) 1.5
´
2.5 mm (0.059
´
0.098 in) ----
End gap (installed) 0.1 ~ 0.3 mm (0.004 ~ 0.012 in) ----
Connecting rods
Crankshaft pin-to-big end bearing
clearance0.058 ~ 0.078 mm (0.0023 ~ 0.0031 in) ----
Bearing color code 2 = Blue, 3·4 = Black, 5·6 = Brown,
7·8 = Green, 9 = Yellow----
Crankshaft
Width A 54.4 ~ 56.0 mm (2.142 ~ 2.205 in) ----
Width B 292.8 ~ 294.0 mm (11.53 ~ 11.57 in) ----
Maximum runout C 0.035 mm
(0.0014 in)
Big end side clearance D 0.16 ~ 0.26 mm (0.006 ~ 0.010 in) ----
Crankshaft journal-to-crankshaft
journal bearing clearance0.036 ~ 0.056 mm (0.0014 ~ 0.0022 in) ----
Bearing color code1·2 = Blue, 3·4 = Black, 5·6 = Brown, 7·8 =
Green, 9·10 = Yellow, 11 = Violet----
Clutch
Clutch type Wet, multiple disc ----
Clutch release method Hydraulic inner push ----
Operation Left-hand operation ----
Recommended fluid Brake fluid DOT4 ----
Friction plates #1
Thickness 2.9 ~ 3.1 mm (0.114 ~ 0.122 in) 2.8 mm
(0.110 in)
Plate quantity 8 ----
Friction plate #2
Thickness 3.7 ~ 3.9 mm (0.146 ~ 0.154 in) 3.6 mm
(0.142 in)
Plate quantity 1 ----Item Standard Limit
B
T
D
FCCC
A
B
E

ENGINE SPECIFICATIONS
SPEC

2 - 10
Clutch plates
Thickness 1.5 ~ 1.7 mm (0.059 ~ 0.067 in) ----
Plate quantity 8 ----
Maximum warpage ---- 0.1 mm
(0.004 in)
Clutch springs
Free length 7.1 mm (0.280 in) ----
Spring quantity 1 spring per valve ----
Transmission
Transmission type Constant mesh, 6-speed ----
Primary reduction system Spur gear ----
Primary reduction ratio 88/47 (1.872) ----
Secondary reduction system Chain drive ----
Secondary reduction ratio 43/17 (2.529) ----
Operation Left-foot operation ----
Gear ratios
1st gear 38/17 (2.235) ----
2nd gear 36/19 (1.895) ----
3rd gear 35/21 (1.667) ----
4th gear 33/23 (1.435) ----
5th gear 31/24 (1.292) ----
6th gear 27/23 (1.174) ----
Maximum main axle runout ---- 0.08 mm
(0.003 in)
Maximum drive axle runout ---- 0.08 mm
(0.003 in)
Shifting mechanism
Shift mechanism type Shift drum ----
Maximum shift fork guide bar
bending ---- 0.05 mm
(0.002 in)
Installed shift rod length 294 mm (11.57 in) ----
Air filter type
Dry element ----
Fuel pump
Pump type Electrical ----
Model (manufacturer) 5FL (MITSUBISHI) ----
Output pressure 450 ~ 600 kPa
(4.5 ~ 6.0 kgf/cm
2

, 64 ~ 85 psi)----
Throttle bodies
ID mark 5FL1 ----
Throttle valve #100 ----
Intake vacuum pressure 15.8 ~ 18.4 kPa
(120 ~ 140 mmHg, 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) ---- Item Standard Limit

CHASSIS SPECIFICATIONS
SPEC

2 - 11
CHASSIS SPECIFICATIONS
Item Standard Limit
Frame
Frame type Diamond ----
Caster angle 22.7˚ ----
Trail 95 mm (3.74 in) ----
Front wheel
Wheel type Cast wheel ----
Rim
Size 17
´
MT3.50 ----
Material Aluminum ----
Wheel travel 120 mm (4.72 in) ----
Wheel runout
Maximum radial wheel runout ---- 1 mm
(0.04 in)
Maximum lateral wheel runout ---- 0.5 mm
(0.02 in)
Rear wheel
Wheel type Cast wheel ----
Rim
Size 17
´
MT6.00 ----
Material Aluminum ----
Wheel travel 138 mm (5.43 in) ----
Wheel runout
Maximum radial wheel runout ---- 1 mm
(0.04 in)
Maximum lateral wheel runout ---- 0.5 mm
(0.02 in)
Front tire
Tire type Tubeless ----
Size 120/70 ZR17 (58W) ----
Model (manufacturer) MTR01A (PIRELLI) ----
Tire pressure (cold)
0 ~ 90 kg (0 ~ 198 lb) 250 kPa (2.5 kg/cm
2

, 3.6 psi) ----
90 kg (198 lb) ~ Maximum load* 250 kPa (2.5 kg/cm
2

, 3.6 psi) ----
High-speed riding 250 kPa (2.5 kg/cm
2

, 3.6 psi) ----
* Load is the total weight of the rider
and accessories.
Minimum tire tread depth ---- 1.6 mm
(0.06 in)

CHASSIS SPECIFICATIONS
SPEC

2 - 12
Rear tire
Tire type Tubeless ----
Size 180/55 ZR17 73W ----
Model (manufacturer) MTR08 (PIRELLI) ----
Tire pressure (cold)
0 ~ 90 kg (0 ~ 198 lb) 250 kPa (2.5 kg/cm
2

, 3.6 psi) ----
90 kg (198 lb) ~ Maximum load* 290 kPa (2.9 kg/cm
2

, 4.1 psi) ----
High-speed riding 250 kPa (2.5 kg/cm
2

, 3.6 psi) ----
* Load is the total weight of the rider
and accessories.
Minimum tire tread depth ---- 1.6 mm
(0.06 in)
Front brakes
Brake type Dual-disc brake ----
Operation Right-hand operation ----
Recommended fluid DOT 4 ----
Brake discs
Diameter ´ thickness 320 ´ 5 mm (12.6 ´ 0.20 in) ----
Minimum thickness ---- 4.5 mm
(0.18 in)
Maximum deflection ---- 0.1 mm
(0.004 in)
Brake pad lining thickness 5.5 mm (0.22 in) 0.5 mm
(0.02 in)
Master cylinder inside diameter 14 mm (0.55 in) ----
Caliper cylinder inside diameter 30.2 mm (1.19 in) and 27 mm (1.06 in) ----
Rear brake
Brake type Single-disc brake ----
Operation Right-foot operation ----
Brake pedal position (from the top
of the brake pedal to the center of
the rider footrest bracket bolt)31~ 36 mm (1.22 ~ 1.42 in) ----
Recommended fluid DOT 4 ----
Brake discs
Diameter ´ thickness 245 ´ 5 mm (9.65 ´ 0.20 in) ----
Minimum thickness ---- 4.5 mm
(0.18 in)
Maximum deflection ---- 0.1 mm
(0.004 in)
Brake pad lining thickness 5.5 mm (0.22 in) 0.5 mm
(0.02 in)
Master cylinder inside diameter 12.7 mm (0.5 in) ----
Caliper cylinder inside diameter 38.2 mm (1.50 in) ----Item Standard Limit