drain bolt YAMAHA YZF-R7 1999 Owners Manual

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 - 24
SPEC
OIL FLOW CHART
Pressure feed
Timing chain area camshaft
Valve lifter Check bolt
Piston
Connecting rod
Big end bearing
Nozzle
Nozzle
Back torque limiter clutch
Starter clutch Main axleMain gallery
Drive axle
Oil filter cartridge
Oil cooler
Relief valve
Oil pump
Oil strainer
Oil pan
Drain bolt Main axle gears
Drive axle gearsCrankshaft journal (#2, #4)
Crankshaft journal (#3, #5)Crankshaft journal (#1)
OIL FLOW CHART

ELECTRICAL SPECIFICATIONSSPEC
2 - 25
COOLANT FLOW CHART
Thermostat assembly
Coolant reservoir
Upper radiator
Lower radiator
Water pump
Drain bolt Oil coolerWater jacket
COOLANT FLOW CHART

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 - 4
CHK
ADJ

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 - 24
CHK
ADJ
CHANGING THE ENGINE OIL
EB303081
CHANGING THE ENGINE OIL
1. Remove:
• bottom cowling
• front cowling
Refer to “COWLINGS”.
2. Start the engine, warm it up for several
minutes, and then turn it off.
3. Place a container under the engine oil
drain bolt.
4. Remove:
• engine oil filler cap 1
• engine oil drain bolt 2
(along with the washer)
5. Drain:
• engine oil
(completely from the crankcase)
1
1

6. If the oil filter cartridge is also to be
replaced, perform the following proce-
dure.
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 oil filter cartridge 1 with
an oil filter wrench 2.
Oil filter wrench
90890-01426
b. Lubricate the O-ring 3 of the new oil
filter cartridge with a thin coat of
engine oil.
ACHTUNG:CAUTION:
Make sure that the O-ring 3 is posi-
tioned correctly in the groove of the oil
filter cartridge.
c. Tighten the new oil filter cartridge to
specification with an oil filter wrench.
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
7. Check:
• engine oil drain bolt washer
Damage ® Replace.
8. Install:
• engine oil drain bolt
T R..
Oil filter cartridge
17 Nm (1.7 m • kg, 12 ft • lb)
T R..43 Nm (4.3 m · kg, 31 ft • lb)

3 - 33
CHK
ADJ
CHANGING THE COOLANT
EB303240
CHANGING THE COOLANT
1. Remove:
• bottom cowling
• front cowling
Refer to “COWLINGS”.
2. Remove:
• coolant reservoir bolts 1
• coolant reservoir cap 2
NOTE:
When draining the coolant from the
coolant reservoir, be sure to tilt the res-
ervoir so that coolant cannot flow
through the coolant reservoir breather
hose 3.
3. Drain:
• coolant
(from the coolant reservoir)
4. Install:
• coolant reservoir bolts
2
2

1

1

5. Remove:
• radiator cap 1
WARNINGWARNING
A hot radiator is under pressure. There-
fore, do not remove the radiator cap
when the engine is hot. Scalding hot
fluid and steam may be blown out,
which could cause serious injury. When
the engine has cooled, open the radiator
cap as follows:
Place a thick rag or a towel over the
radiator cap and slowly turn the radia-
tor cap counterclockwise toward the
detent to allow any residual pressure to
escape. When the hissing sound has
stopped, turn the radiator cap counter-
clockwise while pressing down on it
and then remove it.
1
1

6. Remove:
• coolant drain bolt 1
(along with the copper washer)
7. Drain:
• coolant

3 - 34
CHK
ADJ
CHANGING THE COOLANT
8. Check:
• copper washer 1
• coolant drain bolt 2
Damage ® Replace.
9. Install:
• coolant drain bolt
T R..7 Nm (0.7 m · kg, 5.1 ft · lb)
10.Fill:
• cooling system
(with the specified amount of the rec-
ommended coolant)
Recommended antifreeze
High-quality ethylene glycol
antifreeze containing corro-
sion inhibitors for aluminum
engines
Mixing ratio
1:1 (antifreeze: water)
Quantity
Total amount
2.75 L
(2.42 lmp qt, 2.91 US qt)
Coolant reservoir capacity
0.25 L
(0.22 lmp qt, 0.26 US qt)
Handling notes for coolant
Coolant is potentially harmful and should
be handled with special care.
WARNINGWARNING
• If coolant splashes in your eyes, thor-
oughly wash them with water and
consult a doctor.
• If coolant splashes on your clothes,
quickly wash it away with water and
then with soap and water.
• If coolant is swallowed, induce vomit-
ing and get immediate medical atten-
tion.

ENG

4 - 32
GENERATOR
EB410000
GENERATOR
Order Job/Part Q’ty Remarks
Removing the stator coil assembly
Remove 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 Throttle stop screw holder 1
2 Generator rotor cover 1
3 Generator rotor cover gasket 1
4 Dowel pin 2
5 Generator rotor bolt 1
6 Generator rotor 1
7 Stator coil assembly coupler 1 Disconnect.
8 Stator coil assembly lead holder 1
9 Stator coil assembly 1
For installation, reverse the removal
procedure.

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)