YAMAHA YZF-R7 1999 Manual PDF

3 - 2
CHK
ADJ

PERIODIC MAINTENANCE AND LUBRICATION
INTERVALS
*
Since these items require special tools, data and technical skills, they should be serviced by a
Yamaha dealer.
NOTE:

• The air filter element needs more frequent service if you are riding in unusually wet or
dusty areas.
• Hydraulic brake system
– Replace the brake fluid or clutch fluid after disassembling the master cylinder, caliper cyl-
inder or release cylinder.
– Check the brake fluid or clutch fluid level and add fluid as required.
– Replace the master cylinder, caliper cylinder and release cylinder oil seals every two
years.
– Replace the brake hoses and clutch hose every four years, or if cracked or damaged.
15
*
Chassis fasteners
• Make sure that all nuts, bolts and screws are properly
tightened.
• Tighten if necessary.
ÖÖ
16 Sidestand
• Check operation.
• Lubricate and repair if necessary.
ÖÖ
17
*
Sidestand switch
• Check operation.
• Replace if necessary.
ÖÖÖ
18
*
Front fork
• Check operation and for oil leakage.
• Correct accordingly.
ÖÖ
19
*
Rear shock
absorber assembly
• Check operation and shock absorber for oil leakage.
• Replace shock absorber assembly if necessary.
ÖÖ
20
*
Rear suspension
relay arm and con-
necting arm pivot-
ing points
• Check operation.
• Lubricate with lithium soap base grease every 24,000
km or 24 months (whichever comes first).
ÖÖ
21
*
Electronic fuel
injection system
• Check engine idling speed, synchronization and
starter operation.
• Adjust if necessary.
ÖÖÖ
22 Engine oil
• Check oil level and vehicle for oil leakage.
• Correct if necessary.
• Change. (Warm engine before draining.)
ÖÖÖ
23Engine oil filter
cartridge
• Replace.
ÖÖ
24
*
Cooling system
• Check coolant level and vehicle for coolant leakage.
• Correct if necessary.
• Change coolant every 24,000 km 24 months (which-
ever comes first).
ÖÖ
No. ITEM CHECKS AND MAINTENANCE JOBSINITIAL
1,000 km EVERY
6,000 km or
6 months
(whichever
comes first)12,000 km or
12 months
(whichever
comes first)
3

3 - 3
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3 - 4
CHK
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FUEL TANK AND AIR FILTER
EB302010
FUEL TANK AND AIR FILTER
Order Job/Part Q’ty Remarks
Removing the fuel tank and air filter
Remove the parts in the order listed.
Fuel Drain.
1 Fuel tank breather hose 1
2 Bolt 2
3 Bolt 2
4 Fuel pump coupler 1 Disconnect.
5 Fuel tank overflow hose 1
6 Fuel return hose 1 Disconnect.
7 Fuel hose 1 Disconnect.
8 Fuel tank 1
9 Air filter case cover 1
10 Air filter element 1
For installation, reverse the removal
procedure.

3 - 5
CHK
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REMOVAL
1. Drain:
• fuel
(completely from the fuel tank)
NOTE:

Remove the fuel tank cap and use a
pump to remove the fuel from the fuel
tank.
The fuel tank must be drained to avoid
leakage at the fuel pump outlet.
2. Disconnect:
• fuel pump coupler
• fuel hose
• fuel return hose
WARNINGWARNING

Gasoline is highly flammable.
Avoid spilling fuel on the hot engine.
NOTE:

Wrap the rag over the fuel hose joints to
avoid spilling fuel.
FUEL TANK AND AIR FILTER

3 - 6
CHK
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EB302020
COWLINGS
Order Job/Part Q’ty Remarks
Removing the front cowling
Remove the parts in the order listed.
1 Bottom cowling 1
2 Rear view mirror 2
3 Front turn signal coupler 2 Disconnect.
4 Front cowling 1
5 Windshield 1
6 Front turn signal 2
For installation, reverse the removal
procedure.
COWLINGS

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Order Job/Part Q’ty Remarks
Removing the rear cowling
Remove the parts in the order listed.
1 Rear fender 1
2 Rear fender panel 1
3 Tail/brake light connector 2 Disconnect.
4 Rear turn signal connector 4 Disconnect.
5 Rear cowling 1
For installation, reverse the removal
procedure.
COWLINGS

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CHK
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COWLINGS
REMOVAL
1. Remove:
• rear cowling
NOTE:

To remove the quick fastener, push its
center in with a screwdriver, then pull
the fastener out.
INSTALLATION
1. Install:
• rear cowling
NOTE:

To install the quick fastener, push its pin
so that it protrudes from the fastener
head, then insert the fastener into the
cowling and push the pin
a
in with a
screwdriver. Make sure that the pin is
flush with the fastener’s head.

3 - 9
CHK
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ADJUSTING THE VALVE CLEARANCE
EB303001
ENGINE
ADJUSTING THE VALVE CLEARANCE
The following procedure applies to all of
the valves.
NOTE:

• Valve clearance adjustment should be
made on a cold engine, at room tem-
perature.
• When the valve clearance is to be mea-
sured or adjusted, the piston must be
at top dead center (TDC) on the com-
pression stroke.
1. Remove:
• bottom cowling
• front cowling
• rear cowling
Refer to “COWLINGS”.
• fuel tank
• air filter case cover
Refer to “FUEL TANK AND AIR FIL-
TER”.
• air filter case
• throttle body assembly
Refer to “ELECTRONIC FUEL INJEC-
TION” IN CHAPTER 6.
• radiator assembly
• thermostat assembly
Refer to “RADIATOR AND THERMO-
STAT” in chapter 5.
2. Disconnect:
• camshaft sensor coupler
• ignition coil couplers
3. Remove:
• ignition coils
• spark plugs
•
cylinder head cover
1

• cylinder head cover gasket
4. Remove:
• pickup coil lead holder
1

• pickup coil rotor cover
2

2
2
1

1

3 - 10
CHK
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ADJUSTING THE VALVE CLEARANCE
5. Measure:
• valve clearance
Out of specification ® Adjust.
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 crankshaft clockwise.
b. When piston #1 is at TDC on the com-
pression stroke, align the TDC
mark a on the pickup coil rotor with
the crankcase mating surface b.
NOTE:
TDC on the compression stroke can be
found when the camshaft lobes are
turned away from each other.
c. Measure the valve clearance with a
thickness gauge 1.
NOTE:
• If the valve clearance is incorrect,
record the measured reading.
• Measure the valve clearance in the fol-
lowing sequence.
Front
d. To measure the valve clearances of
the other cylinders, starting with cyl-
inder #1 at TDC, turn the crankshaft
counterclockwise as specified in the
following table.
õDegrees that the crankshaft is turned
counterclockwise
‚Cylinder
ëCombustion cycle
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
Valve clearance (cold)
Intake valve
0.20 ~ 0.25 mm
(0.0079 ~ 0.0098 in)
Exhaust valve
0.25 ~ 0.30 mm
(0.0098 ~ 0.0119 in)
Valve clearance measuring sequence
Cylinder #1 ® #2 ® #4 ® #3
Cylinder #2 180˚
Cylinder #4 360˚
Cylinder #3 540˚
H H
T
T
a
a
b
b

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CHK
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ADJUSTING THE VALVE CLEARANCE
6. Remove:
• timing chain tensioner
• timing chain guide (exhaust side)
• intake camshaft caps
• exhaust camshaft caps
• timing chain
(from the camshaft sprockets)
• intake camshaft
• exhaust camshaft
NOTE:
• Refer to “CAMSHAFTS” in chapter 4.
• When removing the timing chain and
camshafts, fasten the timing chain
with a wire to retrieve it if it falls into
the crankcase.
7. Adjust:
• valve clearance
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. Remove the valve lifter 1 and the
valve pad 2.
NOTE:
• Cover the timing chain opening with a
rag to prevent the valve pad from fall-
ing into the crankcase.
• Make a note of the position of each
valve lifter 1 and valve pad 2 so that
they can be installed in the correct
place.
b. Select the proper valve pad from the
following table.
NOTE:
• The thickness a of each valve pad is
marked in hundredths of millimeters
on the side that touches the valve
lifter.
• Since valve pads of various sizes are
originally installed, the valve pad num-
ber must be rounded in order to reach
the closest equivalent to the original.Valve pad thick-
ness rangeAvailable valve
pads
Nos.
120 ~
2401.20 ~
2.40 mm 25 thicknesses in
0.05 mm incre-
ments