engine YAMAHA YZF-R7 1999 Manual PDF

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

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

ENG
4 - 39
CLUTCH
EB405000
CLUTCH
Order Job/Part Q’ty Remarks
Removing the clutch coverRemove 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 Clutch cover 1
2 Clutch cover gasket 1
3 Dowel pin 2
For installation, reverse the removal
procedure.

4 - 47
ENGCLUTCH
4. Bend the lock washer tab along a flat
side of the nut.
5. Lubricate:
• friction plates
• clutch plates
(with the recommended lubricant)
Recommended lubricant
Engine oil
6. Install:
• friction plates 1 - 3.00 mm (0.12 in)
• clutch plates 2
• friction plate 3 - 3.85 mm (0.15 in)
NOTE:
First, install a friction plate and then
alternate between a clutch plate and a
friction plate.
13
2

ENG
4 - 48
SHIFT SHAFT
EB408000
SHIFT SHAFT
Order Job/Part Q’ty Remarks
Removing the shift shaft and stop-
per leverRemove the parts in the order listed.
Drive sprocket cover Refer to “ENGINE”.
1 Shift shaft cover 1
2 Shift shaft cover gasket 1
3 Dowel pin 2
4 Shift shaft 1
5 Shift shaft spring 1
6 Spacer 1
7 Stopper lever spring 1
8 Stopper lever 1
9 Circlip 1
10 Collar 1
11 Shift shaft spring stopper 1
For installation, reverse the removal
procedure.

ENG
4 - 50
OIL PAN AND OIL PUMP
EB411000
OIL PAN AND OIL PUMP
Order Job/Part Q’ty Remarks
Removing the oil pan and oil pumpRemove the parts in the order listed.
Engine oil Drain.
Refer to “CHANGING THE ENGINE
OIL” in chapter 3.
Coolant Drain.
Refer to “CHANGING THE COOLANT”
in chapter 3.
Radiator assembly and water pump
outlet pipeRefer to “RADIATOR AND THERMO-
STAT” and “OIL COOLER” in chapter 5.
Exhaust pipe assembly Refer to “ENGINE”.
1 Oil level switch connector 1 Disconnect.
2 Oil level switch 1
3 Oil level switch lead holder 1
4 Oil pan 1
5 Oil pan gasket 1
6 Dowel pin 2

4 - 54
ENGOIL PAN AND OIL PUMP
3. Check:
• oil pump operation
Unsmooth ® Repair or replace the
defective part(-s).
Refer to “WATER PUMP” in chapter 5.
EB411410
CHECKING THE RELIEF VALVE
1. Check:
• relief valve body 1
• relief valve 2
• spring 3
• O-ring 4
Damage/wear ® Replace the defective
part(-s).
EB411421
CHECKING THE OIL DELIVERY PIPE AND
OIL PIPE
1. Check:
• oil delivery pipe 1
• oil pipe 2
Damage ® Replace.
Obstruction ® Wash and blow out
with compressed air.
EB411430
CHECKING THE OIL STRAINER
1. Check:
• oil strainer 1
Damage ® Replace.
Contaminants ® Clean with engine oil.
EB411701
ASSEMBLING THE OIL PUMP
1. Lubricate:
• inner rotor
• outer rotor
• impeller shaft
(with the recommended lubricant)
Recommended lubricant
Engine oil

4 - 55
ENGOIL PAN AND OIL PUMP
2. Check:
• oil pump operation
Refer to “CHECKING THE OIL PUMP”.
EB411710
INSTALLING THE OIL PUMP
1. Install:
• oil pump 1
NOTE:
Install the oil/water pump assembly
drive chain onto the oil/water pump
assembly driven sprocket.
T R..12 Nm (1.2 m · kg, 8.7 ft · lb)
EB411720
INSTALLING THE OIL STRAINER
1. Install:
• oil strainer 1
NOTE:
The arrow a on the oil strainer housing
must point towards the front of the
engine.
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)
EB411730
INSTALLING THE OIL PAN
1. Install:
• dowel pins
• oil pan gasket
• oil pan 1
• oil level switch 2
• engine oil drain bolt 3
WARNINGWARNING
Always use new copper washers.
NOTE:
• Tighten the oil pan bolts in stages and
in a crisscross pattern.
• Lubricate the oil level switch O-ring
with lithium soap base grease.
New
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)
T R..43 Nm (4.3 m · kg, 31 ft · lb)

ENG
4 - 56
CRANKCASE
CRANKCASE
Order Job/Part Q’ty Remarks
Separating the crankcaseRemove the parts in the order listed.
Engine Refer to “ENGINE”.
Cylinder head Refer to “CYLINDER HEAD”.
Pickup coil and pickup coil rotor Refer to “PICKUP COIL”.
Stator coil assembly Refer to “GENERATOR”.
Clutch housing and starter clutch
idle gearRefer to “CLUTCH”.
Oil/water pump assembly Refer to “OIL PAN AND OIL PUMP”.
1 Timing chain 1
2 Oil/water pump assembly drive
chain guide1
3 Oil/water pump assembly drive
chain1

4 - 59
ENGCRANKCASE
EB412100
DISASSEMBLING THE CRANKCASE
1. Remove:
• crankcase bolts
NOTE:
• Loosen each bolt 1/4 of a turn at a
time, in stages and in a crisscross pat-
tern. After all of the bolts are fully loos-
ened, remove them.
• Loosen the bolts in decreasing numeri-
cal order (refer to the numbers in the
illustration).
• The numbers embossed on the crank-
case indicate the crankcase tightening
sequence.
2. Place the engine upside down.
3. Remove:
• lower crankcase
ACHTUNG:CAUTION:
Tap on one side of the crankcase with a
soft-face hammer. Tap only on rein-
forced portions of the crankcase, not on
the crankcase mating surfaces. Work
slowly and carefully and make sure that
the crankcase halves separate evenly.
M9 ´ 105 mm bolts: 1 ~ @
M8 ´ 60 mm bolt: K, L
M6 ´ 70 mm bolts: G, I, O, Q
M6 ´ 64 mm bolts: F, N
M6 ´ 60 mm bolt: M
M6 ´ 55 mm bolts: A ~ E
M6 ´ 50 mm bolt: H
M6 ´ 45 mm bolts: J, P, R
4. Remove:
• dowel pins
5. Remove:
• crankshaft journal lower bearing
(from the lower crankcase)
NOTE:
Identify the position of each crankshaft
journal lower bearing so that it can be
reinstalled in its original place.