1999 YAMAHA YZF-R7 lock

ENGINE SPECIFICATIONS
SPEC

2 - 6
Valve stem runout ---- 0.01 mm
(0.0004 in)
Valve seat width
Intake 0.9 ~ 1.1 mm (0.035 ~ 0.043 in) 1.6 mm
(0.06 in)
Exhaust 0.9 ~ 1.1 mm (0.035 ~ 0.043 in) 1.6 mm
(0.06 in)
Valve springs
Inner spring
Free length
Intake 32.35 mm (1.27 in) 30.73 mm
(1.21 in)
Exhaust 28.82 mm (1.13 in) 27.37 mm
(1.08 in)
Installed length (valve closed)
Intake 27.96 mm (1.10 in) ----
Exhaust 24.6 mm (0.97 in) ----
Compressed spring force
(installed)
Intake 101 ~ 117 N
(10.30 ~ 11.93 kgf, 22.7 ~ 26.3 lb)----
Exhaust 106 ~ 122 N
(10.81 ~ 12.44 kgf, 23.8 ~ 27.4 lb)----
Spring tilt
Intake ----2.5˚ /1.4 mm
(2.5˚/0.055 in)
Exhaust ----2.5˚ /1.3 mm
(2.5˚/0.051 in)
Winding direction (top view)
Intake Counter clockwise ----
Exhaust Counter clockwise ----Item Standard Limit

ENGINE SPECIFICATIONS
SPEC

2 - 7
Outer springs
Free length
Intake 36.42 mm (1.43 in) 34.60 mm
(1.36 in)
Exhaust 33.91 mm (1.34 in) 32.21 mm
(1.27 in)
Installed length (valve closed)
Intake 32.03 mm (1.26 in) ----
Exhaust 30.25 mm (1.19 in) ----
Compressed spring force
(installed)
Intake 230 ~ 266 N
(23.45 ~ 27.12 kgf, 51.7 ~ 59.8 lb)----
Exhaust 286 ~ 329 N
(29.16 ~ 33.55 kgf, 62.3 ~ 74.0 lb)----
Spring tilt
Intake ----2.5˚ /1.6 mm
(2.5˚/0.063 in)
Exhaust ----2.5˚ /1.5 mm
(2.5˚/0.059 in)
Winding direction (top view)
Intake Clockwise ----
Exhaust Clockwise ----
Cylinders
Cylinder arrangement Forward-inclined, parallel 4-cylinder ----
Bore

´

stroke 72
´
46 mm (2.83
´
1.81 in) ----
Compression ratio 11.4:1 ----
Bore 72.000 ~ 72.008 mm
(2.8346 ~ 2.8350 in)----
Maximum taper ---- 0.05 mm
(0.0016 in)
Maximum out of round ---- 0.05 mm
(0.0016 in) Item Standard Limit

CHASSIS SPECIFICATIONSSPEC
2 - 13
Front suspension
Suspension type Telescopic fork ----
Front fork type Coil spring/oil damper ----
Front fork travel 120 mm (4.72 in) ----
Spring
Free length 240 mm (9.45 in) ----
Spacer length 127 mm (5.00 in) ----
Installed length 226 mm (8.90 in) ----
Spring rate (K1) 9.3 N/mm (0.95 kgf/mm, 53.2 lb/in)
Spring stroke (K1) 0 ~ 120 mm (0 ~ 4.72 in) ----
Optional spring available No ----
Fork oil
Recommended oil Suspension oil “01” or equivalent ----
Quantity (each front fork leg) 460 cm
3 (16.2 Imp oz, 15.6 US oz) ----
Level (from the top of the outer
tube, with the outer tube fully
down, and without the fork
spring)170 mm (6.69 in) ----
Damper adjusting rod locknut dis-
tance31 mm (1.22 in) ----
Spring preload adjusting positions
Minimum 0 [0 mm ( 0 in)] ----
Standard 14 [14 mm (0.55 in)] ----
Maximum 18-1/2 [18.5 mm (0.73 in)] ----
Rebound damping adjusting posi-
tions
Minimum* 17 ----
Standard* 6 ----
Maximum* 1 ----
Compression damping adjusting
positions
Minimum* 20 ----
Standard* 6 ----
Maximum* 1 ----
* from the fully turned-in positionItem Standard Limit

2 - 19
SPEC
Shift shaft cover Bolt M6 6 12 1.2 8.7
Oil baffle plate Bolt M6 5 10 1.0 7.2
LT
Timing mark accessing screw – M8 1 15 1.5 11
Starter clutch Bolt M6 3 12 1.2 8.7
LT
Clutch boss Nut M20 1 70 7.0 50Use a lock
washer.
Clutch spring Bolt M6 6 8 0.8 5.8
Drive sprocket Nut M18 1 70 7.0 50Use a lock
washer.
Main axle bearing housing Screw M6 3 12 1.2 8.7
LT
Shift drum retainer Bolt M6 2 10 1.0 7.2LT
Shift shaft spring stopper Bolt M8 1 22 2.2 16LT
Shift rod locknut Nut M6 2 7 0.7 5.1
Shift arm Bolt M6 1 10 1.0 7.2
Stator coil Bolt M6 3 10 1.0 7.2
LT
Neutral switch – M10 1 20 2.0 14
Pickup coil Screw M5 2 4 0.4 2.9
LT
Thermo switch – M16 1 23 2.3 17
Camshaft sensor Bolt M6 1 10 1.0 7.2
LT
Speed sensor Bolt M6 1 10 1.0 7.2LT
Coolant temperature sensor – M12 1 18 1.8 13
Intake air temperature sensor – M12 1 18 1.8 13
Intake air pressure sensor Screw M5 2 5 0.5 3.6
LT
Atmospheric pressure sensor Screw M5 2 5 0.5 3.6LT
Air funnel Bolt M6 8 10 1.0 7.2LT
Throttle body assembly Bolt M6 16 10 1.0 7.2
Injector 2 cover Bolt M5 8 8 0.8 5.8
LT
Fuel distributor Bolt M6 6 10 1.0 7.2LT
Injector fuel pipe 1,3 and 4 Union bolt M12 3 30 3.0 22
Injector fuel pipe 2 – M12 1 30 3.0 22
Fuel hose joint pipe Bolt M5 1 6 0.6 4.3
LT
Pressure sensor bracket Bolt M5 2 8 0.8 5.8LT
Item Fastener Thread size Q’tyTightening torque
Remarks
Nm m·kgf ft·lb
TIGHTENING TORQUES

2 - 27
SPEC
1Rear brake switch coupler
2Pickup coil lead
3Thermo switch lead
4Wire harness
5Rear brake switch lead
6Ground lead
7Starter motor leadFasten the coolant reservoir breather hose, thermo
switch lead and thermostat assembly breather hose
with a plastic locking tie. Do not crush the breather
hoses with the plastic locking tie.
õFasten the right handlebar switch lead with a plastic
clamp.
CABLE ROUTING

3 - 10
CHK
ADJ

ADJUSTING THE VALVE CLEARANCE
5. Measure:
• valve clearance
Out of specification ® Adjust.
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.
c. Measure the valve clearance with a
thickness gauge 1.
NOTE:
• If the valve clearance is incorrect,
record the measured reading.
• Measure the valve clearance in the fol-
lowing sequence.
Front
d. To measure the valve clearances of
the other cylinders, starting with cyl-
inder #1 at TDC, turn the crankshaft
counterclockwise as specified in the
following table.
õDegrees that the crankshaft is turned
counterclockwise
‚Cylinder
ëCombustion cycle
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
Valve clearance (cold)
Intake valve
0.20 ~ 0.25 mm
(0.0079 ~ 0.0098 in)
Exhaust valve
0.25 ~ 0.30 mm
(0.0098 ~ 0.0119 in)
Valve clearance measuring sequence
Cylinder #1 ® #2 ® #4 ® #3
Cylinder #2 180˚
Cylinder #4 360˚
Cylinder #3 540˚
H H
T
T
a
a
b
b

3 - 12
CHK
ADJ
ADJUSTING THE VALVE CLEARANCE
c. Round off the original valve pad num-
ber according to the following table.
EXAMPLE:
Original valve pad number = 148 (thickness
= 1.48 mm)
Rounded value = 150
d. Locate the rounded number of the
original valve pad and the measured
valve clearance in the valve pad
selection table. The point where the
column and row intersect is the new
valve pad number.
NOTE:
The new valve pad number is only an
approximation. The valve clearance
must be measured again and the above
steps should be repeated if the measure-
ment is still incorrect.
e. Install the new valve pad 1 and the
valve lifter 2.
NOTE:
• Lubricate the valve pad with molybde-
num disulfide grease.
• Lubricate the valve lifter with molyb-
denum disulfide oil.
• The valve lifter must turn smoothly
when rotated by hand.
• Install the valve lifter and the valve pad
in the correct place.
f. Install the exhaust and intake cam-
shafts, timing chain and camshaft
caps.
NOTE:
• Refer to “CAMSHAFTS” in chapter 4.
• Lubricate the camshaft lobes and cam-
shaft journals.
• First, install the exhaust camshaft.
• Align the camshaft marks with the
camshaft cap marks.
• Turn the crankshaft counterclockwise
several full turns to seat the parts.Last digit Rounded value
0 or 2 0
55
810
T R..
Camshaft cap bolt
10 Nm (1.0 m • kg, 7.2 ft • lb)

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