1999 YAMAHA YZF-R7 oil

4 - 76
ENGCRANKSHAFT
a. Clean the crankshaft journal bearings,
crankshaft journals, and bearing por-
tions of the crankcase.
b. Place the upper crankcase upside
down on a bench.
c. Install the crankshaft journal upper
bearings 1 and the crankshaft into
the upper crankcase.
NOTE:
Align the projections a on the crank-
shaft journal upper bearings with the
notches b in the upper crankcase.
d. Put a piece of Plastigauge
Ò 2 on each
crankshaft journal.
NOTE:
Do not put the PlastigaugeÒ over the oil
hole in the crankshaft journal.
e. Install the crankshaft journal lower
bearings into the lower crankcase and
assemble the crankcase.
NOTE:
• Align the projections a on the crank-
shaft journal lower bearings with the
notches b in the lower crankcase.
• Do not move the crankshaft until the
clearance measurement has been
completed.
f. Tighten the bolts to specification in
the tightening sequence cast on the
crankcase.
NOTE:
Lubricate the crankcase bolt threads
with engine oil.
T R..
Bolt 1 ~ @
32 Nm (3.2 m • kg, 23 ft • lb)
Bolt A ~ E, G ~ J, M, O ~ R
12 Nm (1.2 m • kg, 8.7 ft • lb)
Bolt F, N
14 Nm (1.4 m • kg, 10 ft • lb)
Bolt K, L
24 Nm (2.4 m • kg, 17 ft • lb)

ENG
4 - 79
TRANSMISSION
EB413000
TRANSMISSION
Order Job/Part Q’ty Remarks
Removing the transmission, shift
drum assembly, and shift forksRemove the parts in the order listed.
Crankcase Separate.
Refer to “CRANKCASE”.
Stopper lever Refer to “SHIFT SHAFT”.
1 Drive axle assembly 1
2 Circlip 1
3 Oil seal 1
4 Bearing 1
5 Shift drum retainer 1
6 Shift fork guide bar 2
7 Spring 4
8 Shift fork “L” 1
9 Shift fork “R” 1

4 - 87
ENGTRANSMISSION
4. Check:
• transmission gear engagement
(each pinion gear to its respective
wheel gear)
Incorrect ® Reassemble the transmis-
sion axle assemblies.
5. Check:
• transmission gear movement
Rough movement ® Replace the
defective part(-s).
6. Check:
• circlips
Bends/damage/looseness ® Replace.
INSTALLING THE TRANSMISSION
1. Install:
• main axle assembly
• shift fork “C”
• shift drum assembly
• shift fork “R”
• shift fork “L”
• springs
• shift fork guide bars
• drive axle assembly
NOTE:
• Install the shift forks so that the
embossed marks “C”, “R”, and “L” are
facing toward the right side of the
engine.
• Carefully position the shift forks so
that they are installed correctly into the
transmission gears.
• Install shift fork “C” into the groove in
the 3rd and 4th pinion gear on the
main axle.
• Install shift fork “L” into the groove in
the 6th wheel gear and shift fork “R”
into the groove in the 5th wheel gear
on the drive axle.
• Make sure that the drive axle bearing
circlip is inserted into the grooves in
the upper crankcase.
2. Check:
• transmission
Rough movement ® Repair.
NOTE:
Oil each gear, shaft, and bearing thor-
oughly.

5 - 2
COOL

RADIATOR AND THERMOSTAT
Order Job/Part Q’ty Remarks
11 Radiator outlet hose 1
12 Lower radiator guard 1
13 Lower radiator 1
14 Lower radiator breather hose 1
15 Radiator joint hose 1
16 Plastic band 1
17 Oil cooler outlet hose 1 Disconnect.
18 Radiator inlet hose 1
19 Horn 1
20 Upper radiator 1
21 Radiator fan 1
22 Upper radiator bracket 2
23 Lower radiator bracket 1
For installation, reverse the removal
procedure.
5

5 - 3
COOL

EB502000
RADIATOR AND THERMOSTAT
Order Job/Part Q’ty Remarks
Removing the thermostat assembly
Remove the parts in the order listed.
Rider seat and fuel tank Refer to “SEATS” and “FUEL TANK” in
chapter 3.
Air filter case and rubber cover Refer to “AIR FILTER CASE AND IGNI-
TION COIL PLATE” in chapter 3.
Carburetor assembly Refer to “CARBURETORS” in chapter 6.
Coolant Drain.
Refer to “CHANGING THE COOLANT”
in chapter 3.
Fuel tank and air filter case cover Refer to “FUEL TANK AND AIR FIL-
TER” in chapter 3.
Air filter case Refer to “ELECTRONIC FUEL INJEC-
TION” in chapter 6.
1 Thermostat assembly 1
2 Thermostat assembly inlet hose 1
RADIATOR AND THERMOSTAT

5 - 9
COOL

OIL COOLER
EB501000
OIL COOLER
Order Job/Part Q’ty Remarks
Removing the oil cooler
Remove the parts in the order listed.
Radiator assembly Refer to “RADIATOR AND THERMO-
STAT”.
Exhaust pipe assembly Refer to “ENGINE” in chapter 4.
Engine oil Drain.
Refer to “CHANGING THE ENGINE
OIL” in chapter 3.
1 Oil cooler outlet hose 1
2 Bolt 1
3 Gasket 1
4 Oil cooler 1
5 Oil cooler inlet hose 1
6 Water pump outlet pipe 1
7 Water jacket joint inlet hose 1
8 Water jacket joint 1
For installation, reverse the removal
procedure.

5 - 10
COOL

OIL COOLER
EB501010
CHECKING THE OIL COOLER
1. Check:
• oil cooler
Cracks/damage
®
Replace.
2. Check:
• oil cooler inlet hose
• oil cooler outlet hose
Cracks/damage/wear
®
Replace.
3. Check:
• water jacket joint
• water jacket joint inlet hose
• water pump outlet hose
Cracks/damage
®
Replace.
EB501020
INSTALLING THE OIL COOLER
1. Clean:
• mating surfaces of the oil cooler and
the crankcase
(with a cloth dampened with lacquer
thinner)
2. Install:
• O-ring
• oil cooler
1
• gasket 2
• bolt 3
NOTE:
• Before installing the oil cooler, lubri-
cate the oil cooler bolt and O-ring with
a thin coat of engine oil.
• Make sure that the O-ring is positioned
properly.
• Align the projection a on the oil
cooler with the projection b in the
crankcase.
1
1

3

3

2

2

a ab
b
New
New
T R..63 Nm (6.3 m · kg, 45 ft · lb)

5 - 11
COOLOIL COOLER
3. Fill:
• cooling system
(with the specified amount of the rec-
ommended coolant)
Refer to “CHANGING THE COOLANT”
in chapter 3.
• crankcase
(with the specified amount of the rec-
ommended engine oil)
Refer to “CHANGING THE ENGINE
OIL” in chapter 3.
4. Check:
• cooling system
Leaks ® Repair or replace any faulty
part.
5. Measure:
• radiator cap opening pressure
Below the specified pressure ®
Replace the radiator cap.
Refer to “CHECKING THE RADIATOR”.