1999 YAMAHA YZF-R7 oil

ENG

4 - 5
ENGINE
Order Job/Part Q’ty Remarks
3 Crankcase breather hose 1
4 Ignition coil 4
5 Camshaft sensor 1
6 Starter motor lead 1 Disconnect.
7 Ground lead 1 Disconnect.
8 Starter motor 1
9 Pickup coil coupler 1 Disconnect.
10 Plastic clip 1
11 Stator coil assembly coupler 1 Disconnect.
12 Sidestand switch coupler 1
13 Oil level switch connector 1 Disconnect.
14 Neutral switch 1
For connecting, reverse the disconnec-
tion procedure.

ENG

4 - 9
CAMSHAFTS
EB401011
Order Job/Part Q’ty Remarks
Removing the camshafts
Remove the parts in the order listed.
Pickup coil rotor cover Refer to “PICKUP COIL”.
1 Timing chain tensioner 1
2 Timing chain tensioner gasket 1
3 Timing chain guide (exhaust side) 1
4 Intake camshaft cap “I” 1
5 Intake camshaft cap “R” 1
6 Intake camshaft cap “L” 1
7 Dowel pin 6
8 Exhaust camshaft cap “E” 1
9 Exhaust camshaft cap “R” 1
10 Exhaust camshaft cap “L” 1
11 Dowel pin 6
NOTE:
During removal, the dowel pins may
still be connected to the camshaft
caps.

4 - 11
ENG

CAMSHAFTS
EB401101
REMOVING THE CAMSHAFTS
1. Align:
• TDC mark on the pickup coil rotor
(with the crankcase mating surface)
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.
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
2. Remove:
• float chamber air vent hose holder
• timing chain tensioner
3. Remove:
• timing chain guide (exhaust side)
4. Remove:
• camshaft caps
• dowel pins
ACHTUNG:CAUTION:

To prevent damage to the cylinder
head, camshafts or camshaft caps,
loosen the camshaft cap bolts in stages
and in a crisscross pattern, working
from the outside in.
H H
T
T
a
a
b
b

5. Remove:
• intake camshaft
1

• exhaust camshaft
2
NOTE:
To prevent the timing chain from falling
into the crankcase, fasten it with a
wire 3.
6. Remove:
• camshaft sprockets 1
(with the flywheel puller 2)
Flywheel puller
90890-01080

4 - 15
ENGCAMSHAFTS
EB401701
INSTALLING THE CAMSHAFTS
1. Install:
• timing chain guide (intake side)
2. Install:
• camshaft sprockets 1
(with the flywheel puller 2)
3. Install:
• exhaust camshaft
• intake camshaft
• exhaust camshaft caps
• intake camshaft caps
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 a
mark on the pickup coil rotor with the
crankcase mating surface b.
c. Install the timing chain onto both
camshaft sprockets and then install
the camshaft sprockets onto the cam-
shafts.
ACHTUNG:CAUTION:
Do not turn the crankshaft when install-
ing the camshaft to avoid damage or
improper valve timing.
NOTE:
Make sure that the punch marks c on
the camshafts face up.
d. Install the exhaust and intake cam-
shaft caps.
NOTE:
Make sure that the punch marks c on
the camshafts are aligned with the
arrow marks d on the camshaft caps.
Out of alignment ® Reinstall.
e. Remove the wire from the timing
chain.
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
Flywheel puller
90890-01080
T R..
Camshaft cap bolt
10 Nm (1.0 m • kg, 7.2 ft • lb)
T R..24 Nm (2.4 m · kg, 17 ft · lb)
H H
T
T
a
a
b
b

4 - 20
ENGCYLINDER HEAD
3. Measure:
• cylinder head warpage
Out of specification ® Resurface the
cylinder head.
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. Place a straightedge 1 and a thick-
ness gauge 2 across the cylinder
head.
b. Measure the warpage.
c. If the limited is exceeded, resurface
the cylinder head as follows.
d. Place a 400 ~ 600 grit wet sandpaper
on the surface plate and resurface the
cylinder head using a figure-eight
sanding pattern.
NOTE:
To ensure an even surface, rotate the
cylinder head several times.
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
Maximum cylinder head
warpage
0.06 mm (0.0024 in)
EB402702
INSTALLING THE CYLINDER HEAD
1. Install:
• cylinder head
• cylinder head nut (1 ~ 10)
• cylinder head bolt (11, 12)
NOTE:
• Lubricate the cylinder head nuts with
engine oil.
• Tighten the cylinder head nuts and
bolts in two stages and in a crisscross
pattern.
• Tighten the nuts and bolts in numeri-
cal order (refer to the numbers in the
illustration).
T R..1st. 20 Nm (2.0 m · kg, 14 ft · lb)
2nd. 50 Nm (5.0 m · kg, 36 ft · lb)
T R..12 Nm (1.2 m · kg, 8.7 ft · lb)

ENG
4 - 21
VALVES AND VALVE SPRINGS
EB403000
VALVES AND VALVE SPRINGS
Order Job/Part Q’ty Remarks
Removing the valves and valve
springsRemove the parts in the order listed.
Cylinder head Refer to “CYLINDER HEAD”.
1 Intake valve lifter 12
2 Intake valve pad 12
3 Intake valve cotter 24
4 Intake valve upper spring seat 12
5 Intake outer valve spring 12
6 Intake inner valve spring 12
7 Intake valve oil seal 12
8 Intake valve lower spring seat 12
9 Intake valve 12
10 Intake valve guide 12

ENG
4 - 22
VALVES AND VALVE SPRINGS
Order Job/Part Q’ty Remarks
11 Exhaust valve lifter 8
12 Exhaust valve pad 8
13 Exhaust valve cotter 16
14 Exhaust valve upper spring seat 8
15 Exhaust outer valve spring 8
16 Exhaust inner valve spring 8
17 Exhaust valve oil seal 8
18 Exhaust valve lower spring seat 8
19 Exhaust valve 8
20 Exhaust valve guide 8
For installation, reverse the removal
procedure.

4 - 24
ENGVALVES AND VALVE SPRINGS
3. Remove:
• valve cotters 1
NOTE:
Remove the valve cotters by compress-
ing the valve spring with the valve spring
compressor 2 and attachment 3.
Valve spring compressor
90890-04019
Attachment
(for the intake valve)
90890-04114
(for the exhaust valve)
90890-04108
4. Remove:
• upper spring seat 1
• valve springs 2
• lower spring seat 3
• valve 4
• oil seal 5
NOTE:
Identify the position of each part very
carefully so that it can be reinstalled in
its original place.
EB403400
CHECKING THE VALVES AND VALVE
GUIDES
The following procedure applies to all of
the valves and valve guides.
1. Measure:
• valve stem-to-valve guide clearance
Out of specification ® Replace the
valve guide.Valve stem-to-valve guide clearance =
Valve guide inside diameter a –
Valve stem diameter b
Valve stem-to-valve guide
clearance
Intake
0.005 ~ 0.029 mm
(0.0002 ~ 0.0011 in)
: 0.06 mm (0.0024 in)
Exhaust
0.010 ~ 0.034 mm
(0.0004 ~ 0.0013 in)
: 0.07 mm (0.0028 in)