1999 YAMAHA YZF-R7 oil

2 - 31
SPEC
KPickup coil lead
LStator coil lead
MSpeed sensor lead
NSidestand switch lead
OOil level switch lead
PCoolant reservoir breather hose
QWire harness
RWire harness lead (to fall detection
switch coupler)
SWire harness lead (to fuse box)
TStarter motor leadUNeutral switch lead
VGround lead
WCoolant temperature sensor coupler
XThrottle cable
Route the wire harness in front of the ignition coils.
õBe sure that there is no slack in the tail/brake light lead
and rear turn signal leads below the rear fender panel.
‚Align the portions of the wire harness, ground lead and
starter motor lead marked with white tape with the lead
holder.
CABLE ROUTING

3 - 2
CHK
ADJ

PERIODIC MAINTENANCE AND LUBRICATION
INTERVALS
*
Since these items require special tools, data and technical skills, they should be serviced by a
Yamaha dealer.
NOTE:

• The air filter element needs more frequent service if you are riding in unusually wet or
dusty areas.
• Hydraulic brake system
– Replace the brake fluid or clutch fluid after disassembling the master cylinder, caliper cyl-
inder or release cylinder.
– Check the brake fluid or clutch fluid level and add fluid as required.
– Replace the master cylinder, caliper cylinder and release cylinder oil seals every two
years.
– Replace the brake hoses and clutch hose every four years, or if cracked or damaged.
15
*
Chassis fasteners
• Make sure that all nuts, bolts and screws are properly
tightened.
• Tighten if necessary.
ÖÖ
16 Sidestand
• Check operation.
• Lubricate and repair if necessary.
ÖÖ
17
*
Sidestand switch
• Check operation.
• Replace if necessary.
ÖÖÖ
18
*
Front fork
• Check operation and for oil leakage.
• Correct accordingly.
ÖÖ
19
*
Rear shock
absorber assembly
• Check operation and shock absorber for oil leakage.
• Replace shock absorber assembly if necessary.
ÖÖ
20
*
Rear suspension
relay arm and con-
necting arm pivot-
ing points
• Check operation.
• Lubricate with lithium soap base grease every 24,000
km or 24 months (whichever comes first).
ÖÖ
21
*
Electronic fuel
injection system
• Check engine idling speed, synchronization and
starter operation.
• Adjust if necessary.
ÖÖÖ
22 Engine oil
• Check oil level and vehicle for oil leakage.
• Correct if necessary.
• Change. (Warm engine before draining.)
ÖÖÖ
23Engine oil filter
cartridge
• Replace.
ÖÖ
24
*
Cooling system
• Check coolant level and vehicle for coolant leakage.
• Correct if necessary.
• Change coolant every 24,000 km 24 months (which-
ever comes first).
ÖÖ
No. ITEM CHECKS AND MAINTENANCE JOBSINITIAL
1,000 km EVERY
6,000 km or
6 months
(whichever
comes first)12,000 km or
12 months
(whichever
comes first)
3

3 - 9
CHK
ADJ

ADJUSTING THE VALVE CLEARANCE
EB303001
ENGINE
ADJUSTING THE VALVE CLEARANCE
The following procedure applies to all of
the valves.
NOTE:

• Valve clearance adjustment should be
made on a cold engine, at room tem-
perature.
• When the valve clearance is to be mea-
sured or adjusted, the piston must be
at top dead center (TDC) on the com-
pression stroke.
1. Remove:
• bottom cowling
• front cowling
• rear cowling
Refer to “COWLINGS”.
• fuel tank
• air filter case cover
Refer to “FUEL TANK AND AIR FIL-
TER”.
• air filter case
• throttle body assembly
Refer to “ELECTRONIC FUEL INJEC-
TION” IN CHAPTER 6.
• radiator assembly
• thermostat assembly
Refer to “RADIATOR AND THERMO-
STAT” in chapter 5.
2. Disconnect:
• camshaft sensor coupler
• ignition coil couplers
3. Remove:
• ignition coils
• spark plugs
•
cylinder head cover
1

• cylinder head cover gasket
4. Remove:
• pickup coil lead holder
1

• pickup coil rotor cover
2

2
2
1

1

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 - 15
CHK
ADJ
SYNCHRONIZING THE THROTTLE BODIES
4. Install:
• vacuum gauge attachments
(into the bolt holes)
• vacuum gauge
(onto the vacuum gauge attachments)
• engine tachometer
(onto the ignition coil of cylinder #1)
NOTE:
Disconnect the ignition coil coupler and
remove the ignition coil 1 of cylinder
#1, remove the rubber cover 2, and
wrap the engine tachometer lead sev-
eral times around section a of the igni-
tion coil. Then, install the ignition coil
and connect the ignition coil coupler.
5. Install:
• fuel tank
Refer to “FUEL TANK AND AIR FIL-
TER”.
6. Start the engine and let it warm up for
several minutes.
Vacuum gauge
90890-03094
Vacuum gauge attachment
90890-03060
Engine tachometer
90890-06760
1 1
2
2
a
a
7. Measure:
• engine idling speed
Out of specification ® Adjust.
Refer to “ADJUSTING THE ENGINE
IDLING SPEED”.
Engine idling speed
1,000 ~ 1,200 r/min
8. Adjust:
• throttle body synchronization
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 air screws 1 to adjust the
vacuum pressure of all throttle bodies
to specification.
NOTE:
Do not turn the synchronizing screws.1 11 1

3 - 17
CHK
ADJADJUSTING THE ENGINE IDLING SPEED/
ADJUSTING THE THROTTLE CABLE FREE PLAY
3. Install:
• engine tachometer
(onto the ignition coil of cylinder #1)
NOTE:
Refer to “SYNCHRONIZING THE THROT-
TLE BODIES” for the engine tachometer
installation.
4. Measure:
• engine idling speed
Out of specification ® Adjust.
Engine tachometer
90890-06760
Engine idling speed
1,000 ~ 1,200 r/min
5. Adjust:
• engine idling speed
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 throttle stop screw 1 in
direction a or b until the specified
engine idling speed is obtained.
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
6. Adjust:
• throttle cable free play
Refer to “ADJUSTING THE THROTTLE
CABLE FREE PLAY”. Direction aEngine idling speed is
increased.
Direction bEngine idling speed is
decreased.
Throttle cable free play
(at the flange of the throttle
grip)
3 ~ 5 mm (0.12 ~ 0.20 in)
a a b b
1
1
EB303031
ADJUSTING THE THROTTLE CABLE FREE
PLAY
NOTE:
Prior to adjusting the throttle cable free
play, the engine idling speed and throt-
tle body synchronization should be
adjusted properly.

3 - 19
CHK
ADJADJUSTING THE THROTTLE CABLE FREE PLAY/
CHECKING THE SPARK PLUGS
Handlebar side
a. Loosen the locknut 4.
b. Turn the adjusting nut 5 in direction
c or d until the specified throttle
cable free play is obtained.
c. Tighten the locknut.
WARNINGWARNING
After adjusting the throttle cable free
play, start the engine and turn the han-
dlebars to the right and to the left to
ensure that this does not cause the
engine idling speed to change.
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
Direction cThrottle cable free play
is increased.
Direction dThrottle cable free play
is decreased.
C C
d d
7
7
5
57
7
4
4
EB303040
CHECKING THE SPARK PLUGS
The following procedure applies to all of
the spark plugs.
1. 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.
2. Disconnect:
• ignition coil couplers
3. Remove:
• ignition coils
• spark plug
ACHTUNG:CAUTION:
Before removing the spark plugs, blow
away any dirt accumulated in the spark
plug wells with compressed air to pre-
vent it from falling into the cylinders.
4. Check:
• spark plug type
Incorrect ® Change.
Spark plugs
Model (manufacturer)
R0256R-10 (NGK)