1999 YAMAHA YZF-R7 Owners Manual

5 - 6
COOL

RADIATOR AND THERMOSTAT
EB500010
CHECKING THE RADIATOR
1. Check:
• radiator fins
Obstruction
®
Clean.
Apply compressed air to the rear of the
radiator.
Damage
®
Repair or replace.
NOTE:

Straighten any flattened fins with a thin,
flat-head screwdriver.
2. Check:
• radiator hoses
Cracks/damage
®
Replace.
3. Measure:
• radiator cap opening pressure
Below the specified pressure
®
Replace the radiator cap.
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. Install the radiator cap tester
1
and
adapter
2
onto the radiator cap
3
.
b. Apply the specified pressure for ten
seconds and make sure that there is
no drop in pressure.
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
Radiator cap opening pressure
95 ~ 125 kPa
(0.95 ~ 1.25 kg/cm
2

,
3.51 ~ 7.78 psi)
Radiator cap tester
90890-01325
Adapter
90890-01352
4. Check:
• radiator fan
Damage
®
Replace.
Malfunction
®
Check and repair.
Refer to “COOLING SYSTEM” in chap-
ter 8.

5 - 7
COOL

RADIATOR AND THERMOSTAT
EB502020
CHECKING THE THERMOSTAT
1. Check:
• thermostat
1

Does not open at 71 ~ 85 ˚C (159.8 ~
185 ˚F)
®
Replace.
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. Suspend the thermostat in a con-
tainer filled with water.
b. Slowly heat the water.
c. Place a thermometer in the water.
d. While stirring the water, observe the
thermostat and thermometer’s indi-
cated temperature.
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
1
Thermostat
2
Thermometer
3
Water
4
Container

Fully closed
õ
Fully open
NOTE:

If the accuracy of the thermostat is in
doubt, replace it. A faulty thermostat
could cause serious overheating or
overcooling.
2. Check:
• thermostat housing cover
• thermostat housing
Cracks/damage
®
Replace.
EB502030
ASSEMBLING THE THERMOSTAT
ASSEMBLY
1. Install:
• thermostat housing
1

• thermostat
2

• thermostat housing cover
NOTE:

Install the thermostat with its breather
hole
a
facing up.
2
1
1
2
a a

5 - 8
COOL

RADIATOR AND THERMOSTAT
INSTALLING THE THERMOSTAT
ASSEMBLY AND RADIATOR
1. Fill:
• cooling system
(with the specified amount of the rec-
ommended coolant)
Refer to “CHANGING THE COOLANT”
in chapter 3.
2. Check:
• cooling system
Leaks
®
Repair or replace any faulty
part.
3. Measure:
• radiator cap opening pressure
Below the specified pressure
®
Replace the radiator cap.
Refer to “CHECKING THE RADIATOR”.

5 - 9
COOL

OIL COOLER
EB501000
OIL COOLER
Order Job/Part Q’ty Remarks
Removing the oil cooler
Remove the parts in the order listed.
Radiator assembly Refer to “RADIATOR AND THERMO-
STAT”.
Exhaust pipe assembly Refer to “ENGINE” in chapter 4.
Engine oil Drain.
Refer to “CHANGING THE ENGINE
OIL” in chapter 3.
1 Oil cooler outlet hose 1
2 Bolt 1
3 Gasket 1
4 Oil cooler 1
5 Oil cooler inlet hose 1
6 Water pump outlet pipe 1
7 Water jacket joint inlet hose 1
8 Water jacket joint 1
For installation, reverse the removal
procedure.

5 - 10
COOL

OIL COOLER
EB501010
CHECKING THE OIL COOLER
1. Check:
• oil cooler
Cracks/damage
®
Replace.
2. Check:
• oil cooler inlet hose
• oil cooler outlet hose
Cracks/damage/wear
®
Replace.
3. Check:
• water jacket joint
• water jacket joint inlet hose
• water pump outlet hose
Cracks/damage
®
Replace.
EB501020
INSTALLING THE OIL COOLER
1. Clean:
• mating surfaces of the oil cooler and
the crankcase
(with a cloth dampened with lacquer
thinner)
2. Install:
• O-ring
• oil cooler
1
• gasket 2
• bolt 3
NOTE:
• Before installing the oil cooler, lubri-
cate the oil cooler bolt and O-ring with
a thin coat of engine oil.
• Make sure that the O-ring is positioned
properly.
• Align the projection a on the oil
cooler with the projection b in the
crankcase.
1
1

3

3

2

2

a ab
b
New
New
T R..63 Nm (6.3 m · kg, 45 ft · lb)

5 - 11
COOLOIL COOLER
3. Fill:
• cooling system
(with the specified amount of the rec-
ommended coolant)
Refer to “CHANGING THE COOLANT”
in chapter 3.
• crankcase
(with the specified amount of the rec-
ommended engine oil)
Refer to “CHANGING THE ENGINE
OIL” in chapter 3.
4. Check:
• cooling system
Leaks ® Repair or replace any faulty
part.
5. Measure:
• radiator cap opening pressure
Below the specified pressure ®
Replace the radiator cap.
Refer to “CHECKING THE RADIATOR”.

5 - 12
COOLWATER PUMP
EB503000
WATER PUMP
Order Job/Part Q’ty Remarks
Removing the impeller shaftRemove the parts in the order listed.
Oil/water pump assembly and oil
pump rotorRefer to “OIL PAN AND OIL PUMP” in
chapter 4.
1 Water pump cover 1
2 O-ring 1
3 Pin 2
4 Impeller shaft (along with the impel-
ler)1
NOTE:
• The water pump and oil pump are
combined into one unit (oil/water
pump assembly).
• It is not necessary to remove the
impeller shaft unless the coolant
level is extremely low or coolant
leaks from the oil pan.

5 - 13
COOLWATER PUMP
Order Job/Part Q’ty Remarks
5 Water pump seal 1
6 Oil seal 1
7 Bearing 1
For installation, reverse the removal
procedure.