torque YAMAHA YZF-R7 1999 Owners Manual

EB004000
SYMBOLS
The following symbols are not relevant to
every vehicle.
Symbols
1
to
9
indicate the subject of
each chapter.
1
General information
2
Specifications
3
Periodic checks and adjustments
4
Overhauling the engine
5
Cooling system
6
Electronic fuel injection
7
Chassis
8
Electrical
Symbols
9
to
F
indicate the following.
9
Serviceable with engine mounted
0
Filling fluid
A
Lubricant
B
Special tool
C
Tightening torque
D
Wear limit, clearance
E
Engine speed
F
Electrical data
Symbols
G
to
L
in the exploded diagrams
indicate the types of lubricants and lubrica-
tion points.
G
Engine oil
H
Gear oil
I
Molybdenum disulfide oil
J
Wheel bearing grease
K
Lithium soap base grease
L
Molybdenum disulfide grease
Symbols
M
to
N
in the exploded diagrams
indicate the following.
MApply locking agent (LOCTITE
â)
NReplace the part 12
34
56
78
90
AB
CD
E F
GHI
JKL
M N
SPEC
CHK
ADJENG
COOLEFI
CHAS–+ELEC
T R..
GME
BLSM
LTNew

EC0A0000
CONTENTS
CHAPTER 1
GENERAL INFORMATION
GIVE SAFETY THE RIGHT OF WAY ........ 1-1
DESCRIPTION ........................................... 1-2
INSTRUMENT AND CONTROL
FUNCTIONS .............................................. 1-4
OPERATION AND IMPORTANT
RIDING POINTS ...................................... 1-12
INCLUDED ACCESSORIES ..................... 1-14
MOTORCYCLE CARE AND
STORAGE ................................................ 1-15
CONSUMER INFORMATION ................. 1-17
TROUBLESHOOTING .............................. 1-18
IMPORTANT INFORMATION ................. 1-20
CHECKING THE CONNECTIONS ........... 1-22
SPECIAL TOOLS ..................................... 1-23
CHAPTER 2
SPECIFICATIONS
GENERAL SPECIFICATIONS .................... 2-1
ENGINE SPECIFICATIONS ....................... 2-2
CHASSIS SPECIFICATIONS ................... 2-11
ELECTRICAL SPECIFICATIONS ............. 2-15
TIGHTENING TORQUES ........................ 2-17
LUBRICATION POINTS AND
LUBRICANT TYPES ................................ 2-22
OIL FLOW CHART ................................... 2-24
COOLANT FLOW CHART ....................... 2-25
CABLE ROUTING .................................... 2-26

1 - 14
OPERATION AND IMPORTANT RIDING POINTS/
INCLUDED ACCESSORIES
EAU01128
Engine break-in
There is never a more important period
in the life of your motorcycle than the
period between zero and 1,600 km. For
this reason we ask that you carefully
read the following material. Because
the engine is brand new, you must not
put an excessive load on it for the first
1,600 km. The various parts in the en-
gine wear and polish themselves to the
correct operating clearances. During
this period, prolonged full throttle oper-
ation, or any condition which might re-
sult in excessive heating of the engine,
must be avoided.
EAU013290 ~ 1,000 km
Avoid operation above 5,500 r/min.
1,000 ~ 1,600 km
Avoid cruising speeds in excess of
7,000 r/min.
EC000052
CAUTION:
After 1,000 km of operation, be sure
to replace the engine oil and oil fil-
ter.
1,600 km and beyond
Proceed with normal riding.
EC000053
CAUTION:
lNever let engine speeds enter
the red zone.
lIf any engine trouble should oc-
cur during the break-in period,
consult a Yamaha dealer imme-
diately.
EAU00460
Parking
When parking the motorcycle, stop the
engine and remove the ignition key.
EW000058
WARNING
The exhaust system is hot. Park the
motorcycle in a place where pedes-
trians or children are not likely to
touch the motorcycle. Do not park
the motorcycle on a slope or soft
ground; the motorcycle may over-
turn.
INCLUDED ACCESSORIES
EAU01575
Tool kit
The tools provided in the owner’s tool
kit are to assist you in the performance
of periodic maintenance. However,
some other tools such as a torque
wrench are also necessary to perform
the maintenance correctly.
The service information included in this
manual is intended to provide you, the
owner, with the necessary information
for completing some of your own pre-
ventive maintenance and minor re-
pairs.
NOTE:
If you do not have necessary tools re-
quired during a service operation, take
your motorcycle to a Yamaha dealer
for service.
EW000063
WARNING
Modifications to this motorcycle not
approved by Yamaha may cause
loss of performance, and render it
unsafe for use. Consult a Yamaha
dealer before attempting any chang-
es.

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 - 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

3 - 30
CHK
ADJCHECKING THE CRANKCASE BREATHER HOSE/
CHECKING THE EXHAUST SYSTEM
3. Install:
• fuel tank
Refer to “FUEL TANK AND AIR FIL-
TER”.
EB303200
CHECKING THE EXHAUST SYSTEM
The following procedure applies to all of
the exhaust pipes and gaskets.
1. Remove:
• radiator assembly
Refer to “RADIATOR AND THERMO-
STAT” in chapter 5.
2. Check:
• exhaust pipe joint 1
• exhaust pipe 2
• muffler 3
Cracks/damage ® Replace.
• gasket 4
Exhaust gas leaks ® Replace.
3. Measure:
• tightening torque
4. Install:
• radiator assembly
Refer to “RADIATOR AND THERMO-
STAT” in chapter 5.
T R..
Exhaust pipe joint bolt 5
20 Nm (2.0 m • kg, 14 ft • lb)
Muffler clamp bolt 6
20 Nm (2.0 m • kg, 14 ft • lb)
Exhaust pipe bolt 7
20 Nm (2.0 m • kg, 14 ft • lb)
Muffler bolt 8
38 Nm (3.8 m • kg, 27 ft • lb)
1
6 3
74
5
2 8