YAMAHA YZF-R7 1999 Workshop Manual

CHASSIS SPECIFICATIONSSPEC
2 - 13
Front suspension
Suspension type Telescopic fork ----
Front fork type Coil spring/oil damper ----
Front fork travel 120 mm (4.72 in) ----
Spring
Free length 240 mm (9.45 in) ----
Spacer length 127 mm (5.00 in) ----
Installed length 226 mm (8.90 in) ----
Spring rate (K1) 9.3 N/mm (0.95 kgf/mm, 53.2 lb/in)
Spring stroke (K1) 0 ~ 120 mm (0 ~ 4.72 in) ----
Optional spring available No ----
Fork oil
Recommended oil Suspension oil “01” or equivalent ----
Quantity (each front fork leg) 460 cm
3 (16.2 Imp oz, 15.6 US oz) ----
Level (from the top of the outer
tube, with the outer tube fully
down, and without the fork
spring)170 mm (6.69 in) ----
Damper adjusting rod locknut dis-
tance31 mm (1.22 in) ----
Spring preload adjusting positions
Minimum 0 [0 mm ( 0 in)] ----
Standard 14 [14 mm (0.55 in)] ----
Maximum 18-1/2 [18.5 mm (0.73 in)] ----
Rebound damping adjusting posi-
tions
Minimum* 17 ----
Standard* 6 ----
Maximum* 1 ----
Compression damping adjusting
positions
Minimum* 20 ----
Standard* 6 ----
Maximum* 1 ----
* from the fully turned-in positionItem Standard Limit

CHASSIS SPECIFICATIONSSPEC
2 - 14
Steering
Steering bearing type Angular ball bearings ----
Rear suspension
Suspension type Swingarm (link suspension) ----
Rear shock absorber assembly
typeCoil spring/gas-oil damper ----
Rear shock absorber assembly
travel63 mm (2.48 in) ----
Spring
Free length 160 mm (6.30 in) ----
Installed length 146 mm (5.75 in) ----
Spring rate (K1) 95 N/mm (9.69 kgf/mm, 543 lb/in) ----
Spring stroke (K1) 0 ~ 63 mm (0 ~ 2.48 in) ----
Optional spring available No ----
Standard spring preload gas/air
pressure 1,200 kPa (12 kgf/cm
2, 171 psi) ----
Spring preload adjusting positions
Minimum 0 [11 mm (0.43 in)] ----
Standard 6 [14 mm (0.55 in)] ----
Maximum 20 [21 mm (0.84 in)] ----
Rebound damping adjusting posi-
tions
Minimum* 50 ----
Standard* 10 ----
Maximum* 0 ----
Compression damping adjusting
positions
Minimum* 25 ----
Standard* 10 ----
Maximum* 0 ----
* from the fully turned-in position
Swingarm
Free play (at the end of the swing-
arm)
Radial ---- 1 mm
(0.04 in)
Axial ---- 1 mm
(0.04 in)
Drive chain
Model (manufacturer) 50ZVM (DAIDO) ----
Link quantity 118 ----
Drive chain slack 40 ~ 50 mm (1.57 ~ 1.97 in) ----
Maximum ten-link section 150.1 mm (5.91 in) ----Item Standard Limit

ELECTRICAL SPECIFICATIONSSPEC
2 - 15
ELECTRICAL SPECIFICATIONS
Item Standard Limit
System voltage12 V ----
Ignition system
Ignition system type C.D.I. ----
Ignition timing 5˚ BTDC at 1,100 r/min ----
Advanced timing 55˚ BTDC at 5,000 r/min ----
Advancer type Throttle position sensor and electrical ----
Pickup coil resistance/color 421 ~ 569 W / Gy–B ----
C.D.I. unit model (manufacturer) F8T19371 (MITSUBISHI) ----
Ignition coils
Model (manufacturer) F6T549 (MITSUBISHI) ----
Minimum ignition spark gap 6 mm (0.24 in) ----
Primary coil resistance 0.16 ~ 0.21 W ----
Secondary coil resistance 5.0 ~ 6.8 kW ----
Throttle position sensor standard
resistance4 ~ 6 kW----
Charging system
System type AC magneto ----
Model (manufacturer) F4T254 (MITSUBISHI) ----
Nominal output 14 V / 22.5 A at 5,000 r/min ----
Stator coil resistance 0.38 ~ 0.46 W at 20˚C (68˚F) ----
Rectifier/regulator
Regulator type Semiconductor-short circuit ----
Model SH650D-11 (SHINDENGEN) ----
No-load regulated voltage 14.1 ~ 14.9 V ----
Capacity 18 A ----
Withstand voltage 200 V ----
Battery
Battery type GT9B-4 ----
Battery voltage/capacity 12V / 8AH ----
Headlight typeHalogen bulb
Indicator light type ´ quantityLED ´ 5
Bulbs (voltage/wattage ´ quantity)
Headlight R. 12 V 60 W ´ 1 / L. 12 V 51 W ´ 1 ----
Auxiliary light 12 V 5 W ´ 2 ----
Tail/brake light 12 V 5 W / 21 W ´ 1 ----
Front turn signal light 12 V 21 W ´ 2 ----
Rear turn signal light 12 V 21 W ´ 2 ----
Meter light 12 V 1.4 W ´ 2 ----

ELECTRICAL SPECIFICATIONSSPEC
2 - 16
Electric starting system
System type Constant mesh ----
Starter motor
Model (manufacturer) SM-14 (MITSUBA) ----
Power output 0.6 kW ----
Armature coil resistance 0.0015 ~ 0.0025 W----
Brushes
Overall length 10 mm (0.40 in) 3.5 mm
(0.14 in)
Spring force 7.16 ~ 9.52 N
(730 ~ 971 gf, 25.8 ~ 34.3 oz)----
Commutator resistance 0.025 ~ 0.035 W----
Commutator diameter 28 mm (1.10 in) 27 mm
(1.06 in)
Mica undercut 0.7 mm (0.03 in) ----
Starter relay
Model (manufacturer) MS5F-631 (JIDECO) ----
Amperage 180 A ----
Coil resistance 4.18 ~ 4.62 W ----
Horn
Horn type Plain ----
Model (manufacturer) ´ quantity YF-12 (NIKKO) ´ 1 ----
Max. amperage 3 A ----
Turn signal relay
Relay type Full-transistor ----
Model (manufacturer) FE246BH (DENSO) ----
Self-cancelling device built-in No ----
Turn signal blinking frequency 75 ~ 95 cycles/min. ----
Wattage 21 W ´ 2 + 3.4 W ----
Oil level switch model (manufac-
turer)071380-0480 (DENSO) ----
Fuel pump relay model (manufac-
turer)G8R-30Y-J (OMRON) ----
Thermo switch model (manufac-
turer)5EB (NIPPON THERMOSTAT) ----
Fuses (amperage ´ quantity)
Main fuse 30 A ´ 1 ----
Headlight fuse 20 A ´ 1 ----
Signaling system fuse 20 A ´ 1 ----
EFI fuse 20 A ´ 1 ----
ECU fuse 7.5 A ´ 1 ----
Radiator fan fuse 7.5 A ´ 1 ----
Backup fuse (odometer) 7.5 A ´ 1 ---- Item Standard Limit

2 - 17
SPEC
EB202001
TIGHTENING TORQUES
GENERAL TIGHTENING TORQUES
This chart specifies tightening torques for
standard fasteners with a standard ISO
thread pitch. Tightening torque specifica-
tions for special components or assemblies
are provided for each chapter of this man-
ual. To avoid warpage, tighten multi-fas-
tener assemblies in a crisscross pattern and
progressive stages until the specified tight-
ening torque is reached. Unless otherwise
specified, tightening torque specifications
require clean, dry threads. Components
should be at room temperature.
A: Width across flats
B: Thread diameter
A
(nut)B
(bolt)General tightening
torques
Nm m•kg ft•lb
10 mm 6 mm 6 0.6 4.3
12 mm 8 mm 15 1.5 11
14 mm 10 mm 30 3.0 22
17 mm 12 mm 55 5.5 40
19 mm 14 mm 85 8.5 61
22 mm 16 mm 130 13.0 94
TIGHTENING TORQUES

2 - 18
SPEC
ENGINE TIGHTENING TORQUES
Item Fastener Thread size Q’tyTightening torque
Remarks
Nm m·kgf ft·lb
Spark plugs – M10 4 13 1.3 9.4
Cylinder head Nut M10 8 50 5.0 36
E
Cylinder head Cap nut M10 2 50 5.0 36E
Cylinder head Bolt M6 2 12 1.2 8.7
Camshaft caps Bolt M6 28 10 1.0 7.2
E
Cylinder head cover Bolt M6 6 12 1.2 8.7
Oil passage check bolt Bolt M8 1 20 2.0 14
Cap bolt (timing chain tensioner) Bolt M6 1 10 1.0 7.2
Camshaft sprocket Bolt M7 4 24 2.4 17
Generator rotor Bolt M10 1 65 6.5 47
E
Pickup coil rotor Bolt M10 1 45 4.5 32E
Water pump inlet pipe Bolt M6 1 10 1.0 7.2LT
Water pump outlet pipe Bolt M6 1 10 1.0 7.2LT
Oil/water pump assembly
driven sprocketBolt M6 1 15 1.5 11LT
Oil pump Bolt M6 1 12 1.2 8.7
Oil cooler Bolt M20 1 63 6.3 45
E
Engine oil drain bolt – M14 1 43 4.3 31
Oil strainer housing Bolt M6 2 10 1.0 7.2
LT
Oil/water pump assembly
driven sprocket coverBolt M6 1 12 1.2 8.7LT
Oil delivery pipe Bolt M6 1 10 1.0 7.2LT
Oil filter bolt Bolt M20 1 70 7.0 50
Oil filter cartridge – M20 1 17 1.7 12
E
Exhaust pipe joints Bolt M8 8 20 2.0 14
Exhaust pipe Bolt M8 1 20 2.0 14
Exhaust pipe bracket Bolt M8 1 24 2.4 17
Exhaust pipe emission check
boltsBolt M6 4 10 1.0 7.2
Muffler clamp Bolt M8 1 20 2.0 14
Muffler Bolt M10 1 38 3.8 27
Muffler bracket Bolt M8 2 28 2.8 20
Crankcase (cylinder head) Stud bolt M10 10 10 1.0 7.2
E
Crankcase Bolt M9 10 32 3.2 23E
Crankcase Bolt M6 2 14 1.4 10E
Crankcase Bolt M6 14 12 1.2 8.7E
Crankcase Bolt M8 2 24 2.4 17E
Generator rotor cover Bolt M6 9 12 1.2 8.7
Clutch cover Bolt M6 9 12 1.2 8.7
Pickup coil rotor cover Bolt M6 7 12 1.2 8.7
TIGHTENING TORQUES

2 - 19
SPEC
Shift shaft cover Bolt M6 6 12 1.2 8.7
Oil baffle plate Bolt M6 5 10 1.0 7.2
LT
Timing mark accessing screw – M8 1 15 1.5 11
Starter clutch Bolt M6 3 12 1.2 8.7
LT
Clutch boss Nut M20 1 70 7.0 50Use a lock
washer.
Clutch spring Bolt M6 6 8 0.8 5.8
Drive sprocket Nut M18 1 70 7.0 50Use a lock
washer.
Main axle bearing housing Screw M6 3 12 1.2 8.7
LT
Shift drum retainer Bolt M6 2 10 1.0 7.2LT
Shift shaft spring stopper Bolt M8 1 22 2.2 16LT
Shift rod locknut Nut M6 2 7 0.7 5.1
Shift arm Bolt M6 1 10 1.0 7.2
Stator coil Bolt M6 3 10 1.0 7.2
LT
Neutral switch – M10 1 20 2.0 14
Pickup coil Screw M5 2 4 0.4 2.9
LT
Thermo switch – M16 1 23 2.3 17
Camshaft sensor Bolt M6 1 10 1.0 7.2
LT
Speed sensor Bolt M6 1 10 1.0 7.2LT
Coolant temperature sensor – M12 1 18 1.8 13
Intake air temperature sensor – M12 1 18 1.8 13
Intake air pressure sensor Screw M5 2 5 0.5 3.6
LT
Atmospheric pressure sensor Screw M5 2 5 0.5 3.6LT
Air funnel Bolt M6 8 10 1.0 7.2LT
Throttle body assembly Bolt M6 16 10 1.0 7.2
Injector 2 cover Bolt M5 8 8 0.8 5.8
LT
Fuel distributor Bolt M6 6 10 1.0 7.2LT
Injector fuel pipe 1,3 and 4 Union bolt M12 3 30 3.0 22
Injector fuel pipe 2 – M12 1 30 3.0 22
Fuel hose joint pipe Bolt M5 1 6 0.6 4.3
LT
Pressure sensor bracket Bolt M5 2 8 0.8 5.8LT
Item Fastener Thread size Q’tyTightening torque
Remarks
Nm m·kgf ft·lb
TIGHTENING TORQUES

2 - 20
SPEC
Crankcase tightening sequence:
TIGHTENING TORQUES

2 - 21
SPEC
CHASSIS TIGHTENING TORQUES
HINWEIS:NOTE:
1.First, tighten the ring nut to approximately 18 Nm (1.8 m • kg, 13 ft • lb) with a torque
wrench, then loosen the ring nut completely.
2.Retighten the ring nut to specification.Item Thread sizeTightening torque
Remarks
Nm m·kgf ft·lb
Upper bracket pinch bolts M8 26 2.6 19
Steering stem nut M28 115 11.5 85
Handlebar pinch bolts M6 13 1.3 9.4
Lower ring nut M30 9 0.9 6.5 See NOTE.
Lower bracket pinch bolts M6 11 1.1 8.0
Front brake hose union bolts M10 30 3.0 22
Front brake master cylinder M6 13 1.3 9.4
Engine mounting
Spacer bolts M16 18 1.8 13
Left front mounting bolts M10 40 4.0 29
Right front mounting bolts M10 40 4.0 29
Rear mounting bolts M10 55 5.5 40
Pinch bolts M8 17 1.7 12
Exhaust pipe bracket M8 24 2.4 17
Pivot shaft nut M18 125 12.5 90
Connecting arms M10 40 4.0 29
Relay arm and connecting arms M10 40 4.0 29
Relay arm M10 40 4.0 29
Rear shock absorber and relay arm M10 40 4.0 29
Rear shock absorber assembly M10 40 4.0 29
Fuel pump and fuel tank M5 4 0.4 2.9
Coolant reservoir and radiator M6 5 0.5 3.6
Rider footrest bracket M8 28 2.8 20
Rear master cylinder M8 23 2.3 17
Rear brake hose union bolts M10 30 3.0 22
Sidestand bracket M8 26 2.6 19
Front wheel axle M20 79 7.9 57
Rear wheel axle M24 150 15.0 110
Rear wheel axle nut M24 45 4.5 32
Front brake caliper and front fork M10 40 4.0 29
Rear brake caliper and bracket M10 40 4.0 29
Brake disc and wheel M6 18 1.8 13
Rear wheel sprocket and rear wheel
drive hubM10 69 6.9 50
Brake caliper and bleed screw M8 6 0.6 4.3
Pinch bolt (front wheel axle) M8 23 2.3 17
TIGHTENING TORQUES

2 - 22
SPEC
EB202000
LUBRICATION POINTS AND LUBRICANT TYPES
ENGINE LUBRICATION POINTS AND LUBRICANT TYPES
Lubrication point Lubricant
Oil seal lips
LS
O-ringsLS
BearingsE
Crankshaft pinsE
Piston surfacesE
Piston pinsE
Connecting rod bolts and nuts MOLYKOTE® G-n paste
Crankshaft journals
E
Camshaft lobesM
Camshaft journalsM
Valve stems (intake and exhaust)M
Valve stem ends (intake and exhaust)E
Water pump impeller shaftE
Oil pump rotors (inner and outer)E
Oil pump housing E
Oil strainer E
Starter clutch idle gear inner surfaceE
Starter clutch assemblyE
Primary driven gearE
Transmission gears (wheel and pinion)M
Main axle and drive axleM
Shift drumE
Shift forks and shift fork guide barsE
Shift shaft E
Shift shaft bossLS
Cylinder head cover mating surfaceYamaha bond
No. 1215
Cylinder head coverYamaha bond
No. 1215
Crankcase mating surfaceYamaha bond
No. 1215
Clutch cover (crankcase mating surface)Yamaha bond
No. 1215
Generator rotor cover (crankcase mating surface)Yamaha bond
No. 1215
Pickup coil rotor cover (crankcase mating surface)Yamaha bond
No. 1215
LUBRICATION POINTS AND LUBRICANT TYPES