1999 YAMAHA YZF-R7 Owners Manual

ENG

4 - 5
ENGINE
Order Job/Part Q’ty Remarks
3 Crankcase breather hose 1
4 Ignition coil 4
5 Camshaft sensor 1
6 Starter motor lead 1 Disconnect.
7 Ground lead 1 Disconnect.
8 Starter motor 1
9 Pickup coil coupler 1 Disconnect.
10 Plastic clip 1
11 Stator coil assembly coupler 1 Disconnect.
12 Sidestand switch coupler 1
13 Oil level switch connector 1 Disconnect.
14 Neutral switch 1
For connecting, reverse the disconnec-
tion procedure.

ENG

4 - 6
ENGINE
Order Job/Part Q’ty Remarks
Removing the engine
Remove the parts in the order listed.
1 Pinch bolt 2 Loosen.
2 Right front mounting bolt 2
3 Left front mounting bolt 2
4 Washer 2
5 Self-locking nut 2
6 Spacer bolt 2 Loosen.
7 Rear mounting bolt 2
8 Spacer 2
9 Mounting bracket 1
For installation, reverse the removal
procedure.
NOTE:
Place a suitable stand under the frame
and engine.

4 - 7
ENG

ENGINE
EB400700
INSTALLING THE ENGINE
1. Install:
• mounting bracket
1

• spacers
2

• rear mounting bolts
3

• washers
4

• left front mounting bolts
5

• right front mounting bolts
6

NOTE:

Do not fully tighten the bolts.
2. Tighten:
• spacer bolts
7

• self-locking nut
8

• left front mounting bolts
• right front mounting bolt
• pinch bolts
9

NOTE:

• Tighten the spacer bolt
7
it to specifi-
cation with a pivot shaft wrench.
• When tightened, the spacer bolt
should be flat against the engine sur-
face.
Pivot shaft wrench
90890-01471
T R..18 Nm (1.8 m · kg, 13 ft · lb)
T R..55 Nm (5.5 m · kg, 40 ft · lb)
T R..40 Nm (4.0 m · kg, 29 ft · lb)
T R..40 Nm (4.0 m · kg, 29 ft · lb)
T R..17 Nm (1.7 m · kg, 12 ft · lb)

3. Install:
• shift arm
1
NOTE:

Align the punch mark
a
in the shift shaft
with the slot in the shift arm.
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)

ENG

4 - 8
CAMSHAFTS
EB401000
CAMSHAFTS
Order Job/Part Q’ty Remarks
Removing the cylinder head cover
Remove the parts in the order listed.
Carburetor assembly Refer to “CARBURETORS” in chapter 6.
Radiator assembly and thermostat
assemblyRefer to “RADIATOR AND THERMO-
STAT” and “THERMOSTAT ASSEM-
BLY” in chapter 5.
1 Spark plug 4
2 Cylinder head cover 1
3 Cylinder head cover gasket 1
4 Timing chain guide (top side) 1
For installation, reverse the removal
procedure.

ENG

4 - 9
CAMSHAFTS
EB401011
Order Job/Part Q’ty Remarks
Removing the camshafts
Remove the parts in the order listed.
Pickup coil rotor cover Refer to “PICKUP COIL”.
1 Timing chain tensioner 1
2 Timing chain tensioner gasket 1
3 Timing chain guide (exhaust side) 1
4 Intake camshaft cap “I” 1
5 Intake camshaft cap “R” 1
6 Intake camshaft cap “L” 1
7 Dowel pin 6
8 Exhaust camshaft cap “E” 1
9 Exhaust camshaft cap “R” 1
10 Exhaust camshaft cap “L” 1
11 Dowel pin 6
NOTE:
During removal, the dowel pins may
still be connected to the camshaft
caps.

ENG

4 - 10
CAMSHAFTS
Order Job/Part Q’ty Remarks
12 Intake camshaft 1
13 Exhaust camshaft 1
14 Intake camshaft sprocket 1
15 Exhaust camshaft sprocket 1
16 Pin 1
17 Timing chain guide (intake side) 1
For installation, reverse the removal
procedure.

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 - 12
ENGCAMSHAFTS
EB401401
CHECKING THE CAMSHAFTS
1. Check:
• camshaft lobes
Blue discoloration/pitting/scratches ®
Replace the camshaft.
2. Measure:
• camshaft lobe dimensions a and b
Out of specification ® Replace the
camshaft.
Camshaft lobe dimensions
limit
Intake camshaft
a 33.31 mm (1.3114 in)
b 24.90 mm (0.9803 in)
Exhaust camshaft
a 32.95 mm (1.2972 in)
b 24.936 mm (0.9817 in)
3. Measure:
• camshaft runout
Out of specification ® Replace.
Maximum camshaft runout
0.03 mm (0.0012 in)
4. Measure:
• camshaft journal-to-camshaft cap
clearance
Out of specification ® Measure the
camshaft journal diameter.
Camshaft journal-to-camshaft
cap clearance
0.035 ~ 0.069 mm
(0.0014 ~ 0.0027 in)