bolt pattern YAMAHA YZF-R7 1999 Owners Manual

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

4 - 11
ENG

CAMSHAFTS
EB401101
REMOVING THE CAMSHAFTS
1. Align:
• TDC mark on the pickup coil rotor
(with the crankcase mating surface)
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.
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
2. Remove:
• float chamber air vent hose holder
• timing chain tensioner
3. Remove:
• timing chain guide (exhaust side)
4. Remove:
• camshaft caps
• dowel pins
ACHTUNG:CAUTION:

To prevent damage to the cylinder
head, camshafts or camshaft caps,
loosen the camshaft cap bolts in stages
and in a crisscross pattern, working
from the outside in.
H H
T
T
a
a
b
b

5. Remove:
• intake camshaft
1

• exhaust camshaft
2
NOTE:
To prevent the timing chain from falling
into the crankcase, fasten it with a
wire 3.
6. Remove:
• camshaft sprockets 1
(with the flywheel puller 2)
Flywheel puller
90890-01080

4 - 13
ENGCAMSHAFTS
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. Install the camshaft into the cylinder
head (without the dowel pins and
camshaft caps).
b. Position a strip of Plastigauge
® 1
onto the camshaft journal as shown.
c. Install the dowel pins and camshaft
caps.
NOTE:
• Tighten the camshaft cap bolts in
stages and in a crisscross pattern,
working from the inner caps out.
• Do not turn the camshaft when mea-
suring the camshaft journal-to-cam-
shaft cap clearance with the
Plastigauge®.
d. Remove the camshaft caps and then
measure the width of the Plasti-
gauge
® 1.
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
T R..
Camshaft cap bolt
10 Nm (1.0 m • kg, 7.2 ft • lb)
5. Measure:
• camshaft journal diameter a
Out of specification ® Replace the
camshaft.
Within specification ® Replace the cylin-
der head and the camshaft caps as a set.
Camshaft journal diameter
24.452 ~ 24.465 mm
(0.9627 ~ 0.9632 in)
EB401421
CHECKING THE TIMING CHAIN,
CAMSHAFT SPROCKETS, AND TIMING
CHAIN GUIDES
The following procedure applies to all of
the camshaft sprockets and timing chain
guides.
1. Check:
• timing chain
Damage/stiffness ® Replace the tim-
ing chain and camshaft sprockets as a
set.

4 - 17
ENGCAMSHAFTS
7. Check:
• TDC mark a
Make sure that the TDC mark is
aligned with the crankcase mating sur-
face b.
• camshaft punch mark c
Make sure that the camshaft punch
mark is aligned with the arrow mark d
on the camshaft cap.
Out of alignment ® Adjust.
Refer to the installation steps above.
H H
T
T
a
a
b
b
8. Measure:
• valve clearance
Out of specification ® Adjust.
Refer to “ADJUSTING THE VALVE
CLEARANCE” in chapter 3.
9. Install:
• cylinder head cover gasket
• cylinder head cover
NOTE:
• Apply bond TB1541 onto the mating
surfaces of the cylinder head cover
and cylinder head cover gasket.
• Apply bond 1215B onto the mating
surfaces of the cylinder head cover
gasket and cylinder head.
• Tighten the cylinder head cover bolts
in stages and in a crisscross pattern.

4 - 19
ENGCYLINDER HEAD
EB402102
REMOVING THE CYLINDER HEAD
1. Remove:
• cylinder head bolts
• cylinder head nuts
NOTE:
• Loosen each bolt and nut 1/2 of a turn
at a time, in stages and in a crisscross
pattern. After all of the bolts and nuts
are fully loosened, remove them.
• Loosen the bolts and nuts in decreas-
ing numerical order (refer to the num-
bers in the illustration).
EB402402
CHECKING THE CYLINDER HEAD
1. Eliminate:
• combustion chamber carbon deposits
(with a rounded scraper)
NOTE:
Do not use a sharp instrument to avoid
damaging or scratching:
• spark plug bore threads
• valve seats
2. Check:
• cylinder head
Damage/scratches ® Replace.
• cylinder head water jacket
Mineral deposits/rust ® Eliminate.

4 - 20
ENGCYLINDER HEAD
3. Measure:
• cylinder head warpage
Out of specification ® Resurface the
cylinder head.
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. Place a straightedge 1 and a thick-
ness gauge 2 across the cylinder
head.
b. Measure the warpage.
c. If the limited is exceeded, resurface
the cylinder head as follows.
d. Place a 400 ~ 600 grit wet sandpaper
on the surface plate and resurface the
cylinder head using a figure-eight
sanding pattern.
NOTE:
To ensure an even surface, rotate the
cylinder head several times.
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
Maximum cylinder head
warpage
0.06 mm (0.0024 in)
EB402702
INSTALLING THE CYLINDER HEAD
1. Install:
• cylinder head
• cylinder head nut (1 ~ 10)
• cylinder head bolt (11, 12)
NOTE:
• Lubricate the cylinder head nuts with
engine oil.
• Tighten the cylinder head nuts and
bolts in two stages and in a crisscross
pattern.
• Tighten the nuts and bolts in numeri-
cal order (refer to the numbers in the
illustration).
T R..1st. 20 Nm (2.0 m · kg, 14 ft · lb)
2nd. 50 Nm (5.0 m · kg, 36 ft · lb)
T R..12 Nm (1.2 m · kg, 8.7 ft · lb)

4 - 33
ENG

GENERATOR
EB410110
REMOVING THE GENERATOR
1. Remove:
• generator rotor cover
1

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.
1
1

2. Remove:
• generator rotor bolt
1

• washer
NOTE:

While holding the generator rotor
2
with the rotor holding tool
3
, loosen the
generator rotor bolt.
Rotor holding tool
90890-01235
3. Remove:
• generator rotor
1
(with the flywheel puller
2
and rotor
holding tool
3
)
Flywheel puller
90890-01080
EB410700
INSTALLING THE GENERATOR
1. Apply:
• sealant
(onto the stator coil assembly lead
grommet)
2. Install:
• generator rotor
• washer
• generator rotor bolt
WARNINGWARNING

Always use a new generator rotor bolt.
ACHTUNG:CAUTION:

• Clean the tapered portion of the crank-
shaft and the generator rotor hub with
lacquer thinner.
• Lubricate the generator rotor bolt
threads with engine oil.
Yamaha bond No. 1215
90890-85505

4 - 34
ENG

GENERATOR
3. Tighten:
• generator rotor bolt
1
NOTE:

While holding the generator rotor
2
with the rotor holding tool
3
, tighten
the generator rotor bolt.
4. Install:
• generator rotor cover
NOTE:

Tighten the generator rotor cover bolts
in stages and in a crisscross pattern.
Rotor holding tool
90890-01235
New
T R..65 Nm (6.5 m · kg, 47 ft · lb)

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

4 - 42
ENGCLUTCH
EB405102
REMOVING THE CLUTCH
1. Remove:
• clutch cover 1
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.
1
1

2. Straighten the lock washer tab.
3. Loosen:
• clutch boss nut 1
NOTE:
While holding the clutch boss 2 with
the clutch holding tool 3, loosen the
clutch boss nut.
Clutch holding tool
90890-04086
EB405400
CHECKING THE FRICTION PLATES
The following procedure applies to all of
the friction plates.
1. Check:
• friction plate
Damage/wear ® Replace the friction
plates as a set.
2. Measure:
• friction plate thickness
Out of specification ® Replace the fric-
tion plates as a set.
NOTE:
Measure the friction plate at four places.
Friction plate #1 thickness
2.9 ~ 3.1 mm
(0.114 ~ 0.122 in)
: 2.8 mm (0.110 in)
Friction plate #2 thickness
3.7 ~ 3.9 mm
(0.146 ~ 0.154 in)
: 3.6 mm (0.142 in)