1999 YAMAHA YZF-R7 fuel filter

3 - 5
CHK
ADJ

REMOVAL
1. Drain:
• fuel
(completely from the fuel tank)
NOTE:

Remove the fuel tank cap and use a
pump to remove the fuel from the fuel
tank.
The fuel tank must be drained to avoid
leakage at the fuel pump outlet.
2. Disconnect:
• fuel pump coupler
• fuel hose
• fuel return hose
WARNINGWARNING

Gasoline is highly flammable.
Avoid spilling fuel on the hot engine.
NOTE:

Wrap the rag over the fuel hose joints to
avoid spilling fuel.
FUEL TANK AND AIR FILTER

3 - 9
CHK
ADJ

ADJUSTING THE VALVE CLEARANCE
EB303001
ENGINE
ADJUSTING THE VALVE CLEARANCE
The following procedure applies to all of
the valves.
NOTE:

• Valve clearance adjustment should be
made on a cold engine, at room tem-
perature.
• When the valve clearance is to be mea-
sured or adjusted, the piston must be
at top dead center (TDC) on the com-
pression stroke.
1. Remove:
• bottom cowling
• front cowling
• rear cowling
Refer to “COWLINGS”.
• fuel tank
• air filter case cover
Refer to “FUEL TANK AND AIR FIL-
TER”.
• air filter case
• throttle body assembly
Refer to “ELECTRONIC FUEL INJEC-
TION” IN CHAPTER 6.
• radiator assembly
• thermostat assembly
Refer to “RADIATOR AND THERMO-
STAT” in chapter 5.
2. Disconnect:
• camshaft sensor coupler
• ignition coil couplers
3. Remove:
• ignition coils
• spark plugs
•
cylinder head cover
1

• cylinder head cover gasket
4. Remove:
• pickup coil lead holder
1

• pickup coil rotor cover
2

2
2
1

1

3 - 18
CHK
ADJ
ADJUSTING THE THROTTLE CABLE FREE PLAY
1. Measure:
• throttle cable free play a
Out of specification ® Adjust.
Throttle cable free play
(at the flange of the throttle
grip)
3 ~ 5 mm (0.12 ~ 0.20 in)
2. Remove:
• fuel tank
• air filter case cover
Refer to “FUEL TANK AND AIR FIL-
TER”.
• air filter case
Refer to “ELECTRONIC FUEL INJEC-
TION” in chapter 6.
3. Adjust:
• throttle cable free play
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
NOTE:
When the throttle is opened, the acceler-
ator cable 1 is pulled.
Throttle body side
a. Loosen the locknut 2 on the accelera-
tor cable.
b. Turn the adjusting bolt 3 in direction
a or b until the specified throttle
cable free play is obtained.
c. Tighten the locknut.
NOTE:
If the specified throttle cable free play
cannot be obtained on the throttle body
side of the cable, use the adjusting nut
on the handlebar side.Direction aThrottle cable free play
is increased.
Direction bThrottle cable free play
is decreased.
3 3
2 2
11
a a
b b

3 - 19
CHK
ADJADJUSTING THE THROTTLE CABLE FREE PLAY/
CHECKING THE SPARK PLUGS
Handlebar side
a. Loosen the locknut 4.
b. Turn the adjusting nut 5 in direction
c or d until the specified throttle
cable free play is obtained.
c. Tighten the locknut.
WARNINGWARNING
After adjusting the throttle cable free
play, start the engine and turn the han-
dlebars to the right and to the left to
ensure that this does not cause the
engine idling speed to change.
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
Direction cThrottle cable free play
is increased.
Direction dThrottle cable free play
is decreased.
C C
d d
7
7
5
57
7
4
4
EB303040
CHECKING THE SPARK PLUGS
The following procedure applies to all of
the spark plugs.
1. Remove:
• fuel tank
• air filter case cover
Refer to “FUEL TANK AND AIR FIL-
TER”.
• air filter case
Refer to “ELECTRONIC FUEL INJEC-
TION” in chapter 6.
2. Disconnect:
• ignition coil couplers
3. Remove:
• ignition coils
• spark plug
ACHTUNG:CAUTION:
Before removing the spark plugs, blow
away any dirt accumulated in the spark
plug wells with compressed air to pre-
vent it from falling into the cylinders.
4. Check:
• spark plug type
Incorrect ® Change.
Spark plugs
Model (manufacturer)
R0256R-10 (NGK)

3 - 21
CHK
ADJ
MEASURING THE COMPRESSION PRESSURE
3. Remove:
• fuel tank
• air filter case cover
Refer to “FUEL TANK AND AIR FIL-
TER”.
• air filter case
• throttle body assembly
Refer to “ELECTRONIC FUEL INJEC-
TION” in chapter 6.
• ignition coil
4. Remove:
• spark plug
ACHTUNG:CAUTION:
Before removing the spark plugs, use
compressed air to blow away any dirt
accumulated in the spark plug wells to
prevent it from falling into the cylinders.
5. Install:
• compression gauge 1
• adapter 2
Compression gauge
90890-03081
Adapter
90890-04136
1
1

2

2

6. Measure:
• compression pressure
Out of specification ® Refer to steps
(c) and (d).
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. Set the main switch to “ON”.
b. With the throttle wide open, crank the
engine until the reading on the com-
pression gauge stabilizes.
Compression pressure (at sea
level)
Minimum
1,500 kPa
(15.0 kg/cm
2, 213 psi)
Standard
1,600 kPa
(16.0 kg/cm
2, 228 psi)
Maximum
1,700 kPa
(17.0 kg/cm
2, 242 psi)

3 - 28
CHK
ADJBLEEDING THE HYDRAULIC CLUTCH SYSTEM/
CLEANING THE AIR FILTER ELEMENT
j. Tighten the bleed screw to specifica-
tion.
k. Fill the clutch fluid reservoir to the
proper level with the recommended
clutch fluid.
Refer to “CHECKING THE CLUTCH
FLUID LEVEL”.
WARNINGWARNING
After bleeding the hydraulic clutch sys-
tem, check the clutch operation.
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..
Bleed screw
6 Nm (0.6 m • kg, 4.3 ft • lb)
EB303130
CLEANING THE AIR FILTER ELEMENT
1. Remove:
• fuel tank
• air filter case cover
• air filter element
Refer to “FUEL TANK AND AIR FIL-
TER”.
2. Clean:
• air filter element
Apply compressed air to the outer sur-
face of the air filter element.
3. Check:
• air filter element
Damage ® Replace.
4. Install:
• air filter element
• air filter case cover
ACHTUNG:CAUTION:
Never operate the engine without the
air filter element installed. Unfiltered air
will cause rapid wear of engine parts
and may damage the engine. Operating
the engine without the air filter element
will also affect the electronic fuel injec-
tion, leading to poor engine perfor-
mance and possible overheating.
5. Install:
• fuel tank
Refer to “FUEL TANK AND AIR FIL-
TER”.

3 - 29
CHK
ADJCHECKING THE FUEL HOSES/
CHECKING THE CRANKCASE BREATHER HOSE
CHECKING THE FUEL HOSES
The following procedure applies to all of
the fuel hoses.
1. Remove:
• fuel tank
• air filter case cover
Refer to “FUEL TANK AND AIR FIL-
TER”.
2. Check:
• fuel hose 1
Cracks/damage ® Replace.
NOTE:
Drain and flush the fuel tank if abrasive
damage to any components of the fuel
line is evident.
1
1

1
1

1
1

1
1

3. Install:
• air filter case cover
• fuel tank
Refer to “FUEL TANK AND AIR FIL-
TER”.
EB303190
CHECKING THE CRANKCASE BREATHER
HOSE
1. Remove:
• fuel tank
Refer to “FUEL TANK AND AIR FIL-
TER”.
2. Check:
• crankcase breather hose 1
Cracks/damage ® Replace.
Loose connection ® Connect properly.
ACHTUNG:CAUTION:
Make sure that the crankcase breather
hose is routed correctly.
1
1

ENG

4 - 4
ENGINE
Order Job/Part Q’ty Remarks
Disconnecting the leads and hoses
Disconnect the parts in the order listed.
Fuel tank and air filter case cover Refer to “FUEL TANK AND AIR FILTER
COVER” in chapter 3.
Air filter case and throttle body
assemblyRefer to “ELECTRONIC FUEL INJEC-
TION” in chapter 6.
Engine oil and oil filter cartridge Drain.
Refer to “CHANGING THE ENGINE
OIL” in chapter 3.
Oil cooler and thermostat assembly Refer to “OIL COOLER” and “THER-
MOSTAT ASSEMBLY” in chapter 5.
1 Battery negative lead 1
2 Battery positive lead 1
ACHTUNG:CAUTION:
First, disconnect the negative lead,
then the positive lead.