1999 YAMAHA YZF-R7 Owners Manual

4 - 13
ENGCAMSHAFTS
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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 - 14
ENGCAMSHAFTS
2. Check:
• camshaft sprocket
More than 1/4 tooth wear a ® Replace
the camshaft sprockets and the timing
chain as a set.
a1/4 tooth
bCorrect
1Timing chain roller
2Camshaft sprocket
3. Check:
• timing chain guide (exhaust side) 1
• timing chain guide (intake side) 2
• timing chain guide (top side) 3
Damage/wear ® Replace the defective
part(-s).
EB401430
CHECKING THE TIMING CHAIN
TENSIONER
1. Check:
• timing chain tensioner
Cracks/damage/rough movement ®
Replace.
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a. Lightly press the timing chain ten-
sioner rod into the timing chain ten-
sioner housing by hand.
NOTE:
While pressing the timing chain ten-
sioner rod, wind it clockwise with a thin
screwdriver 1 until it stops.
b. Remove the screwdriver and slowly
release the timing chain tensioner
rod.
c. Make sure that the timing chain ten-
sioner rod comes out of the timing
chain tensioner housing smoothly. If
there is rough movement, replace the
timing chain tensioner.
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

4 - 15
ENGCAMSHAFTS
EB401701
INSTALLING THE CAMSHAFTS
1. Install:
• timing chain guide (intake side)
2. Install:
• camshaft sprockets 1
(with the flywheel puller 2)
3. Install:
• exhaust camshaft
• intake camshaft
• exhaust camshaft caps
• intake camshaft caps
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a. Turn the crankshaft clockwise.
b. When piston #1 is at TDC on the com-
pression stroke, align the TDC a
mark on the pickup coil rotor with the
crankcase mating surface b.
c. Install the timing chain onto both
camshaft sprockets and then install
the camshaft sprockets onto the cam-
shafts.
ACHTUNG:CAUTION:
Do not turn the crankshaft when install-
ing the camshaft to avoid damage or
improper valve timing.
NOTE:
Make sure that the punch marks c on
the camshafts face up.
d. Install the exhaust and intake cam-
shaft caps.
NOTE:
Make sure that the punch marks c on
the camshafts are aligned with the
arrow marks d on the camshaft caps.
Out of alignment ® Reinstall.
e. Remove the wire from the timing
chain.
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Flywheel puller
90890-01080
T R..
Camshaft cap bolt
10 Nm (1.0 m • kg, 7.2 ft • lb)
T R..24 Nm (2.4 m · kg, 17 ft · lb)
H H
T
T
a
a
b
b

4 - 16
ENGCAMSHAFTS
4. Install:
• timing chain guide (exhaust side)
5. Install:
• timing chain tensioner
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a. Lightly press the timing chain ten-
sioner rod into the timing chain ten-
sioner housing by hand.
b. While pressing the timing chain ten-
sioner rod, wind it clockwise with a
thin screwdriver 1 until it stops.
c. With the screwdriver still inserted
into the timing chain tensioner, install
the timing chain tensioner and gasket
onto the cylinder block. Then, tighten
the timing chain tensioner bolts to the
specified torque.
WARNINGWARNING
Always use a new gasket.
NOTE:
The “UP” mark on the timing chain ten-
sioner should face up.
d. Remove the screwdriver, make sure
that the timing chain tensioner rod
releases, and tighten the cap bolt to
the specified torque.
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..
Timing chain tensioner bolt
10 Nm (1.0 m • kg, 7.2 ft • lb)
T R..
Cap bolt
10 Nm (1.0 m • kg, 7.2 ft • lb)
6. Turn:
• crankshaft
(several turns counterclockwise)

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.

ENG
4 - 18
CYLINDER HEAD
EB402000
CYLINDER HEAD
Order Job/Part Q’ty Remarks
Removing the cylinder headRemove the parts in the order listed.
Engine Refer to “ENGINE”.
Intake and exhaust camshafts Refer to “CAMSHAFTS”.
1 Cylinder head 1
2 Cylinder head gasket 1
3 Dowel pin 2
For installation, reverse the removal
procedure.

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.
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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.
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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)