1999 YAMAHA YZF-R7 Owners Manual

4 - 85
ENGTRANSMISSION
EB413100
REMOVING THE TRANSMISSION
1. Remove:
• main axle assembly 1
(with the Torx
Ò wrench T30)
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. Insert two bolts 2 of the proper size,
as shown in the illustration, into the
main axle assembly bearing housing.
b. Tighten the bolts until they contact
the crankcase surface.
c. Continue tightening the bolts until the
main axle assembly comes free from
the upper crankcase.
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
EB413400
CHECKING THE SHIFT FORKS
The following procedure applies to all of
the shift forks.
1. Check:
• shift fork cam follower 1
• shift fork pawl 2
Bends/damage/scoring/wear ®
Replace the shift fork.
2. Check:
• shift fork guide bar
Roll the shift fork guide bar on a flat
surface.
Bends ® Replace.
WARNINGWARNING
Do not attempt to straighten a bent
shift fork guide bar.

4 - 86
ENGTRANSMISSION
3. Check:
• shift fork movement
(along the shift fork guide bar)
Rough movement ® Replace the shift
fork(-s) and shift fork guide bar as a
set.
EB413410
CHECKING THE SHIFT DRUM ASSEMBLY
1. Check:
• shift drum grooves
Damage/scratches/wear ® Replace the
shift drum assembly.
• shift drum segment 1
Damage/wear ® Replace the shift
drum assembly.
• shift drum bearing 2
Damage/pitting ® Replace the shift
drum assembly.
EB413422
CHECKING THE TRANSMISSION
1. Measure:
• main axle runout
(with a centering device and dial
gauge 1)
Out of specification ® Replace the
main axle.
Maximum main axle runout
0.08 mm (0.003 in)
2. Measure:
• drive axle runout
(with a centering device and dial
gauge 1)
Out of specification ® Replace the
drive axle.
Maximum drive axle runout
0.08 mm (0.003 in)
3. Check:
• transmission gears
Blue discoloration/pitting/wear ®
Replace the defective gear(-s).
• transmission gear dogs
Cracks/damage/rounded edges ®
Replace the defective gear(-s).

4 - 87
ENGTRANSMISSION
4. Check:
• transmission gear engagement
(each pinion gear to its respective
wheel gear)
Incorrect ® Reassemble the transmis-
sion axle assemblies.
5. Check:
• transmission gear movement
Rough movement ® Replace the
defective part(-s).
6. Check:
• circlips
Bends/damage/looseness ® Replace.
INSTALLING THE TRANSMISSION
1. Install:
• main axle assembly
• shift fork “C”
• shift drum assembly
• shift fork “R”
• shift fork “L”
• springs
• shift fork guide bars
• drive axle assembly
NOTE:
• Install the shift forks so that the
embossed marks “C”, “R”, and “L” are
facing toward the right side of the
engine.
• Carefully position the shift forks so
that they are installed correctly into the
transmission gears.
• Install shift fork “C” into the groove in
the 3rd and 4th pinion gear on the
main axle.
• Install shift fork “L” into the groove in
the 6th wheel gear and shift fork “R”
into the groove in the 5th wheel gear
on the drive axle.
• Make sure that the drive axle bearing
circlip is inserted into the grooves in
the upper crankcase.
2. Check:
• transmission
Rough movement ® Repair.
NOTE:
Oil each gear, shaft, and bearing thor-
oughly.

5 - 1
COOL

RADIATOR AND THERMOSTAT
EB500000
COOLING SYSTEM
RADIATOR AND THERMOSTAT
Order Job/Part Q’ty Remarks
Removing the radiator
Remove the parts in the order listed.
Bottom cowling and front cowling Refer to “COWLINGS” in chapter 3.
Coolant Drain.
Refer to “CHANGING THE COOLANT”
in chapter 3.
1 Coolant reservoir breather hose 1
2 Coolant reservoir hose 1
3 Coolant reservoir 1
4 Thermo switch 1
5 Thermostat assembly breather hose 1 Disconnect.
6 Water pump inlet pipe 1
7 Water pump breather hose 1
8 Radiator outlet pipe breather hose 1
9 Water pump inlet hose 1
10 Radiator outlet pipe 1
5

5 - 2
COOL

RADIATOR AND THERMOSTAT
Order Job/Part Q’ty Remarks
11 Radiator outlet hose 1
12 Lower radiator guard 1
13 Lower radiator 1
14 Lower radiator breather hose 1
15 Radiator joint hose 1
16 Plastic band 1
17 Oil cooler outlet hose 1 Disconnect.
18 Radiator inlet hose 1
19 Horn 1
20 Upper radiator 1
21 Radiator fan 1
22 Upper radiator bracket 2
23 Lower radiator bracket 1
For installation, reverse the removal
procedure.
5

5 - 3
COOL

EB502000
RADIATOR AND THERMOSTAT
Order Job/Part Q’ty Remarks
Removing the thermostat assembly
Remove the parts in the order listed.
Rider seat and fuel tank Refer to “SEATS” and “FUEL TANK” in
chapter 3.
Air filter case and rubber cover Refer to “AIR FILTER CASE AND IGNI-
TION COIL PLATE” in chapter 3.
Carburetor assembly Refer to “CARBURETORS” in chapter 6.
Coolant Drain.
Refer to “CHANGING THE COOLANT”
in chapter 3.
Fuel tank and air filter case cover Refer to “FUEL TANK AND AIR FIL-
TER” in chapter 3.
Air filter case Refer to “ELECTRONIC FUEL INJEC-
TION” in chapter 6.
1 Thermostat assembly 1
2 Thermostat assembly inlet hose 1
RADIATOR AND THERMOSTAT

5 - 4
COOL

RADIATOR AND THERMOSTAT
Order Job/Part Q’ty Remarks
3 Thermostat assembly breather hose 1
4 Coolant temperature sensor 1
5 Copper washer 1
6 Plastic band 1
7 Thermostat assembly inlet pipe 1
For installation, reverse the removal
procedure.

5 - 5
COOL

1
3
2
T R..10 Nm (1.0 m • kg, 7.2 ft • Ib)

RADIATOR AND THERMOSTAT
EB502010
Order Job/Part Q’ty Remarks
Disassembling the thermostat
assembly
Remove the parts in the order listed.
1
Thermostat housing cover 1
2
Thermostat 1
3
Thermostat housing 1
For assembly, reverse the disassembly
procedure.