1999 YAMAHA YZF-R7 torque

2 - 24
SPEC
OIL FLOW CHART
Pressure feed
Timing chain area camshaft
Valve lifter Check bolt
Piston
Connecting rod
Big end bearing
Nozzle
Nozzle
Back torque limiter clutch
Starter clutch Main axleMain gallery
Drive axle
Oil filter cartridge
Oil cooler
Relief valve
Oil pump
Oil strainer
Oil pan
Drain bolt Main axle gears
Drive axle gearsCrankshaft journal (#2, #4)
Crankshaft journal (#3, #5)Crankshaft journal (#1)
OIL FLOW CHART

3 - 30
CHK
ADJCHECKING THE CRANKCASE BREATHER HOSE/
CHECKING THE EXHAUST SYSTEM
3. Install:
• fuel tank
Refer to “FUEL TANK AND AIR FIL-
TER”.
EB303200
CHECKING THE EXHAUST SYSTEM
The following procedure applies to all of
the exhaust pipes and gaskets.
1. Remove:
• radiator assembly
Refer to “RADIATOR AND THERMO-
STAT” in chapter 5.
2. Check:
• exhaust pipe joint 1
• exhaust pipe 2
• muffler 3
Cracks/damage ® Replace.
• gasket 4
Exhaust gas leaks ® Replace.
3. Measure:
• tightening torque
4. Install:
• radiator assembly
Refer to “RADIATOR AND THERMO-
STAT” in chapter 5.
T R..
Exhaust pipe joint bolt 5
20 Nm (2.0 m • kg, 14 ft • lb)
Muffler clamp bolt 6
20 Nm (2.0 m • kg, 14 ft • lb)
Exhaust pipe bolt 7
20 Nm (2.0 m • kg, 14 ft • lb)
Muffler bolt 8
38 Nm (3.8 m • kg, 27 ft • lb)
1
6 3
74
5
2 8

3 - 44
CHK
ADJ
CHECKING AND ADJUSTING THE STEERING HEAD
3. Remove:
• bottom cowling
• front cowling
Refer to “COWLINGS”.
4. Remove:
• front brake fluid reservoir 1
• clutch fluid reservoir 2
2
2
1
1

5. Loosen:
• upper bracket pinch bolts 1
• handlebar pinch bolts 2
6. Remove:
• upper bracket bolts 3
• handlebars
(from the upper bracket)
1
1

3
3

2

2

7. Remove:
• steering stem nut 1
• washer 2
• upper bracket 3
2
2
1
1
3
3

8. Adjust:
• steering head
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a. Remove the lock washer 1, the upper
ring nut 2, and the rubber washer 3.
b. Loosen the lower ring nut 4 and then
tighten it to specification with a ring
nut wrench 5.
NOTE:
Set the torque wrench at a right angle to
the steering nut wrench.
Steering nut wrench
90890-01403
T R..
Lower ring nut (initial tighten-
ing torque)
18 Nm (1.8 m • kg, 13 ft • lb)

3 - 45
CHK
ADJ
CHECKING AND ADJUSTING THE STEERING HEAD
c. Loosen the lower ring nut completely,
then tighten it to specification.
WARNINGWARNING
Do not overtighten the lower ring nut.
d. Check the steering head for looseness
or binding by turning the front fork all
the way in both directions. If any
binding is felt, remove the lower
bracket and check the upper and
lower bearings.
Refer to “STEERING HEAD” in chap-
ter 7.
e. Install the rubber washer 3.
f. Install the upper ring nut 2.
g. Finger tighten the upper ring nut 2,
then align the slots of both ring nuts.
If necessary, hold the lower ring nut
and tighten the upper ring nut until
their slots are aligned.
h. Install the lock washer 1.
NOTE:
Make sure that the lock washer tabs a
sit correctly in the ring nut slots b.
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T R..
Lower ring nut (final tightening
torque)
9 Nm (0.9 m • kg, 6.5 ft • lb)
9. Install:
• steering stem nut
• upper bracket bolt
• handlebar pinch bolt
• upper bracket pinch bolt
10.Measure:
• steering head tension
(with the motorcycle still on the stand)
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NOTE:
Make sure that all of the cables and
wires are properly routed.
a. Point the front wheel straight ahead.
b. Install a plastic locking tie 1 loosely
around the end of the handlebar as
shown.
c. Hook a spring gauge 2 onto the plas-
tic locking tie.
T R..115 Nm (11.5 m · kg, 85 ft · lb)
T R..13 Nm (1.3 m · kg, 9.4 ft · lb)
T R..13 Nm (1.3 m · kg, 9.4 ft · lb)
T R..26 Nm (2.6 m · kg, 16 ft · lb)

4 - 16
ENGCAMSHAFTS
4. Install:
• timing chain guide (exhaust side)
5. Install:
• timing chain tensioner
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. 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.
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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)

ENG
4 - 41
CLUTCH
Order Job/Part Q’ty Remarks
14 Back torque limiter outer boss 1
15 Back torque limiter bearing 1
16 Back torque limiter inner boss 1
17 Thrust plate 1
18 Thrust washer 1
19 Clutch housing 1
20 Bearing 1
21 Starter clutch gear 1
22 Bearing 1
23 Starter clutch assembly 1
24 Circlip 1
25 Starter clutch idle gear 1
For installation, reverse the removal
procedure.

4 - 44
ENGCLUTCH
EB405450
CHECKING THE CLUTCH BOSS
1. Check:
• clutch boss splines
Damage/pitting/wear ® Replace the
clutch boss.
NOTE:
Pitting on the clutch boss splines will
cause erratic clutch operation.
EB405460
CHECKING THE PRESSURE PLATE
1. Check:
• pressure plate 1
Cracks/damage ® Replace.
• bearing 2
Damage/wear ® Replace.
CHECKING THE PUSH RODS AND BALL
1. Check:
• push rod #1 1
• push rod #2 2
• ball 3
Damage/wear ® Replace the pull rods
and ball as a set.
2. Check:
• push rod bearing 4
Damage/wear ® Replace.
CHECKING THE BACK TORQUE LIMITER
1. Check:
• back torque limiter outer boss splines
Damage/pitting/wear ® Replace the
back torque limiter outer boss.

4 - 45
ENGCLUTCH
2. Check:
• back torque limiter clutch
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a. Install the back torque limiter bearing
and back torque limiter outer boss
onto the back torque limiter inner
boss and hold the back torque limiter
inner boss.
b. When turning the back torque limiter
outer boss clockwise , the back
torque limiter inner boss and back
torque limiter outer boss should
engage, otherwise the back torque
limiter is faulty and must be replaced.
c. When turning the back torque limiter
outer boss counterclockwise õ, it
should turn freely, otherwise the back
torque limiter is faulty and must be
replaced.
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CHECKING THE STARTER CLUTCH
1. Check:
• starter clutch gear
• starter clutch idle gear
Chips/pitting/roughness/wear ®
Replace the defective part(-s).
2. Check:
• starter clutch operation
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a. Install the starter clutch gear 1 onto
the starter clutch2 and hold the
starter clutch.
b. When turning the starter clutch gear
clockwise , the starter clutch and
the starter clutch gear should engage,
otherwise the starter clutch is faulty
and must be replaced.
c. When turning the starter clutch gear
counterclockwise õ, it should turn
freely, otherwise the starter clutch is
faulty and must be replaced.
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