1999 YAMAHA YZF-R7 check engine

4 - 54
ENGOIL PAN AND OIL PUMP
3. Check:
• oil pump operation
Unsmooth ® Repair or replace the
defective part(-s).
Refer to “WATER PUMP” in chapter 5.
EB411410
CHECKING THE RELIEF VALVE
1. Check:
• relief valve body 1
• relief valve 2
• spring 3
• O-ring 4
Damage/wear ® Replace the defective
part(-s).
EB411421
CHECKING THE OIL DELIVERY PIPE AND
OIL PIPE
1. Check:
• oil delivery pipe 1
• oil pipe 2
Damage ® Replace.
Obstruction ® Wash and blow out
with compressed air.
EB411430
CHECKING THE OIL STRAINER
1. Check:
• oil strainer 1
Damage ® Replace.
Contaminants ® Clean with engine oil.
EB411701
ASSEMBLING THE OIL PUMP
1. Lubricate:
• inner rotor
• outer rotor
• impeller shaft
(with the recommended lubricant)
Recommended lubricant
Engine oil

4 - 55
ENGOIL PAN AND OIL PUMP
2. Check:
• oil pump operation
Refer to “CHECKING THE OIL PUMP”.
EB411710
INSTALLING THE OIL PUMP
1. Install:
• oil pump 1
NOTE:
Install the oil/water pump assembly
drive chain onto the oil/water pump
assembly driven sprocket.
T R..12 Nm (1.2 m · kg, 8.7 ft · lb)
EB411720
INSTALLING THE OIL STRAINER
1. Install:
• oil strainer 1
NOTE:
The arrow a on the oil strainer housing
must point towards the front of the
engine.
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)
EB411730
INSTALLING THE OIL PAN
1. Install:
• dowel pins
• oil pan gasket
• oil pan 1
• oil level switch 2
• engine oil drain bolt 3
WARNINGWARNING
Always use new copper washers.
NOTE:
• Tighten the oil pan bolts in stages and
in a crisscross pattern.
• Lubricate the oil level switch O-ring
with lithium soap base grease.
New
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)
T R..43 Nm (4.3 m · kg, 31 ft · lb)

4 - 68
ENGCONNECTING RODS AND PISTONS
4. Calculate:
• piston pin-to-piston pin bore clearance
Out of specification ® Replace the pis-
ton pin.
Piston pin-to-piston pin bore clearance =
Piston pin bore diameter (in the
piston) –
Piston pin outside diameter
Piston pin-to-piston pin bore
clearance
0.004 ~ 0.020 mm
(0.00016 ~ 0.00079 in)
: 0.070 mm (0.0028 in)
CHECKING THE BIG END BEARINGS
1. Measure:
• crankshaft pin-to-big end bearing
clearance
Out of specification ® Replace the big
end bearings.
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
The following procedure applies to all of
the connecting rods.
ACHTUNG:CAUTION:
Do not interchange the big end bearings
and connecting rods. To obtain the cor-
rect crankshaft pin-to-big end bearing
clearance and prevent engine damage,
the big end bearings must be installed
in their original positions.
a. Clean the big end bearings, crank-
shaft pins, and bearing portions of
the connecting rods.
b. Install the big end upper bearing into
the connecting rod and the big end
lower bearing into the connecting rod
cap.
NOTE:
Align the projections a on the big end
bearings with the notches b in the con-
necting rod and connecting rod cap.
Crankshaft pin-to-big end
bearing clearance
0.058 ~ 0.078 mm
(0.0023 ~ 0.0031 in)

4 - 75
ENGCRANKSHAFT
EB412110
REMOVING THE CRANKSHAFT
1. Remove:
• crankshaft 1
• crankshaft journal upper bearings
(from the upper crankcase)
NOTE:
Identify the position of each crankshaft
journal upper bearing so that it can be
reinstalled in its original place.
EB412403
CHECKING THE CRANKSHAFT
1. Measure:
• crankshaft runout
Out of specification ® Replace the
crankshaft.
Maximum crankshaft runout
0.035 mm (0.0014 in)
2. Check:
• crankshaft journal surfaces
• crankshaft pin surfaces
• bearing surfaces
Scratches/wear ® Replace the crank-
shaft.
CHECKING THE CRANKSHAFT JOURNAL
BEARINGS
1. Measure:
• crankshaft journal-to-crankshaft jour-
nal bearing clearance
Out of specification ® Replace the
crankshaft journal bearings.
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
ACHTUNG:CAUTION:
Do not interchange the crankshaft jour-
nal bearings. To obtain the correct
crankshaft journal-to-crankshaft journal
bearing clearance and prevent engine
damage, the crankshaft journal bearings
must be installed in their original posi-
tions.
Crankshaft journal-to-crank-
shaft journal bearing clearance
0.036 ~ 0.056 mm
(0.0014 ~ 0.0022 in)

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 - 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”.

6 - 10
EFI

ELECTRONIC FUEL INJECTION
CHECKING THE PRESSURE REGULATOR
1. Check:
• pressure regulator
Damage
®
Replace.
EAS00502
CHECKING AND ADJUSTING THE
THROTTLE POSITION SENSOR
NOTE:

Before adjusting the throttle position
sensor, the engine idling speed should
be properly adjusted.
1. Check:
• throttle position sensor
(installed on the throttle body)
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. Disconnect the throttle position sen-
sor coupler from the throttle position
sensor.
b. Connect the pocket tester (
W

´
1k) to
the throttle position sensor.
c. Measure the maximum throttle posi-
tion sensor resistance.
Out of specification
®
Replace the
throttle position sensor.
Positive tester probe
®

blue terminal
1
Negative tester probe
®

black/blue terminal
2
Maximum throttle position
sensor resistance
4.0 ~ 6.0 k
W
at 20 ˚C (68 ˚F)
(blue — black/blue)
B/LYL
231