1999 YAMAHA YZF-R7 bolt pattern

4 - 37
ENG

PICKUP COIL
REMOVING THE PICKUP COIL ROTOR
1. Remove:
• pickup coil lead holder
1

• pickup coil rotor cover
2

NOTE:

Loosen each bolt 1/4 of a turn at a time,
in stages and in a crisscross pattern.
After all of the bolts are fully loosened,
remove them.
2
2
1

1

2. Remove:
• pickup coil rotor bolt
1

• washer
• pickup coil rotor
2

NOTE:

While holding the generator rotor
3
with the rotor holding tool
4, loosen the
pickup coil rotor bolt.
Rotor holding tool
90890-01235
2
2

1

1

INSTALLING THE PICKUP COIL ROTOR
1. Install:
• pickup coil rotor 1
• washer
• pickup coil rotor bolt
NOTE:
When installing the pickup coil rotor,
align the groove 2 in the crankshaft
sprocket with the projection a in the
pickup coil rotor.
ACHTUNG:CAUTION:
Lubricate the pickup coil rotor bolt
threads with engine oil.
1
1

2

2
a
a

4 - 42
ENGCLUTCH
EB405102
REMOVING THE CLUTCH
1. Remove:
• clutch cover 1
NOTE:
Loosen each bolt 1/4 of a turn at a time,
in stages and in a crisscross pattern.
After all of the bolts are fully loosened,
remove them.
1
1

2. Straighten the lock washer tab.
3. Loosen:
• clutch boss nut 1
NOTE:
While holding the clutch boss 2 with
the clutch holding tool 3, loosen the
clutch boss nut.
Clutch holding tool
90890-04086
EB405400
CHECKING THE FRICTION PLATES
The following procedure applies to all of
the friction plates.
1. Check:
• friction plate
Damage/wear ® Replace the friction
plates as a set.
2. Measure:
• friction plate thickness
Out of specification ® Replace the fric-
tion plates as a set.
NOTE:
Measure the friction plate at four places.
Friction plate #1 thickness
2.9 ~ 3.1 mm
(0.114 ~ 0.122 in)
: 2.8 mm (0.110 in)
Friction plate #2 thickness
3.7 ~ 3.9 mm
(0.146 ~ 0.154 in)
: 3.6 mm (0.142 in)

4 - 53
ENGOIL PAN AND OIL PUMP
EB411100
REMOVING THE OIL PAN
1. Remove:
• oil level switch 1
• oil pan 2
• oil pan gasket
• dowel pins
NOTE:
Loosen each bolt 1/4 of a turn at a time,
in stages and in a crisscross pattern.
After all of the bolts are fully loosened,
remove them.
REMOVING THE OIL PUMP
1. Remove:
• oil/water pump assembly driven
sprocket
Flywheel puller
90890-01080
EB411400
CHECKING THE OIL PUMP
1. Check:
• oil/water pump assembly driven
sprocket 1
• oil pump housing 2
Cracks/damage/wear ® Replace the
defective part(-s).
2. Measure:
• inner rotor-to-outer rotor tip clearance
a
• outer rotor-to-oil pump housing clear-
ance b
Out of specification ® Replace the oil
pump.
1 Inner rotor
2 Outer rotor
3 Oil pump housing
Inner rotor-to-outer rotor tip
clearance
0.09 ~ 0.15 mm
(0.004 ~ 0.006 in)
Outer rotor-to-oil pump hous-
ing clearance
0.03 ~ 0.08 mm
(0.001 ~ 0.003 in)

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)

7 - 5
CHAS

FRONT WHEEL AND BRAKE DISCS
EB700416
CHECKING THE BRAKE DISCS
The following procedure applies to both of
the brake discs.
1. Check:
• brake disc
Damage/galling
®
Replace.
2. Measure:
• brake disc deflection
Out of specification
®
Correct the
brake disc deflection or replace the
brake disc.
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. Place the motorcycle on a suitable
stand so that the wheel is elevated.
b. Before measuring the front brake disc
deflection, turn the handlebars to the
left or right to ensure that the front
wheel is stationary.
c. Remove the brake caliper.
d. Hold the dial gauge at a right angle
against the brake disc surface.
e. Measure the deflection 1.5 mm
(0.06 in) below the edge of the brake
disc.
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
Max. brake disc deflection
Front: 0.1 mm (0.004 in)
Rear: 0.1 mm (0.004 in)
3. Measure:
• brake disc thickness
Measure the brake disc thickness at a
few different locations.
Out of specification
®
Replace.
Min. brake disc thickness
Front: 4.5 mm (0.18 in)
Rear: 4.5 mm (0.18 in)
4. Adjust:
• brake disc deflection
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 brake disc.
b. Rotate the brake disc by one bolt
hole.
c. Install the brake disc.
NOTE:

Tighten the brake disc bolts in stages
and in a crisscross pattern.

7 - 6
CHAS

FRONT WHEEL AND BRAKE DISCS
d. Measure the brake disc deflection.
e. If out of specification, repeat the
adjustment steps until the brake disc
deflection is within specification.
f. If the brake disc deflection cannot be
brought within specification, replace
the brake disc.
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..

Brake disc bolt
18 Nm (1.8 m • kg, 13 ft • lb)
LOCTITE
Ò

EB700725
INSTALLING THE FRONT WHEEL
1. Lubricate:
• wheel axle
• oil seal lips
Recommended lubricant
Lithium soap base grease
2. Install:
• brake discs
NOTE:

• Apply locking agent (LOCTITE
Ò

) 648 to
the threads of the brake disc bolts.
• Tighten the brake disc bolts in stages
and in a crisscross pattern.
T R..18 Nm (1.8 m · kg, 13 ft • lb)

3. Tighten:
• wheel axle
1
• wheel axle pinch bolt
2
ACHTUNG:CAUTION:

Before tightening the wheel axle nut,
push down hard on the handlebars sev-
eral times and check if the front fork
rebounds smoothly.
1
1

2
2

T R..79 Nm (7.9 m · kg, 57 ft · lb)
T R..23 Nm (2.3 m · kg, 17 ft · lb)