1999 YAMAHA YZF-R7 engine

ENG

4 - 6
ENGINE
Order Job/Part Q’ty Remarks
Removing the engine
Remove the parts in the order listed.
1 Pinch bolt 2 Loosen.
2 Right front mounting bolt 2
3 Left front mounting bolt 2
4 Washer 2
5 Self-locking nut 2
6 Spacer bolt 2 Loosen.
7 Rear mounting bolt 2
8 Spacer 2
9 Mounting bracket 1
For installation, reverse the removal
procedure.
NOTE:
Place a suitable stand under the frame
and engine.

4 - 7
ENG

ENGINE
EB400700
INSTALLING THE ENGINE
1. Install:
• mounting bracket
1

• spacers
2

• rear mounting bolts
3

• washers
4

• left front mounting bolts
5

• right front mounting bolts
6

NOTE:

Do not fully tighten the bolts.
2. Tighten:
• spacer bolts
7

• self-locking nut
8

• left front mounting bolts
• right front mounting bolt
• pinch bolts
9

NOTE:

• Tighten the spacer bolt
7
it to specifi-
cation with a pivot shaft wrench.
• When tightened, the spacer bolt
should be flat against the engine sur-
face.
Pivot shaft wrench
90890-01471
T R..18 Nm (1.8 m · kg, 13 ft · lb)
T R..55 Nm (5.5 m · kg, 40 ft · lb)
T R..40 Nm (4.0 m · kg, 29 ft · lb)
T R..40 Nm (4.0 m · kg, 29 ft · lb)
T R..17 Nm (1.7 m · kg, 12 ft · lb)

3. Install:
• shift arm
1
NOTE:

Align the punch mark
a
in the shift shaft
with the slot in the shift arm.
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)

ENG
4 - 18
CYLINDER HEAD
EB402000
CYLINDER HEAD
Order Job/Part Q’ty Remarks
Removing the cylinder headRemove the parts in the order listed.
Engine Refer to “ENGINE”.
Intake and exhaust camshafts Refer to “CAMSHAFTS”.
1 Cylinder head 1
2 Cylinder head gasket 1
3 Dowel pin 2
For installation, reverse the removal
procedure.

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 - 32
GENERATOR
EB410000
GENERATOR
Order Job/Part Q’ty Remarks
Removing the stator coil assembly
Remove the parts in the order listed.
Bottom cowling and front cowling Refer to “COWLINGS” in chapter 3.
Engine oil Drain.
Refer to “CHANGING THE ENGINE
OIL” in chapter 3.
1 Throttle stop screw holder 1
2 Generator rotor cover 1
3 Generator rotor cover gasket 1
4 Dowel pin 2
5 Generator rotor bolt 1
6 Generator rotor 1
7 Stator coil assembly coupler 1 Disconnect.
8 Stator coil assembly lead holder 1
9 Stator coil assembly 1
For installation, reverse the removal
procedure.

4 - 33
ENG

GENERATOR
EB410110
REMOVING THE GENERATOR
1. Remove:
• generator rotor cover
1

NOTE:

Loosen each bolt 1/4 of a turn at a time,
in stages and in a crisscross pattern.
After all of the bolts are fully loosened,
remove them.
1
1

2. Remove:
• generator rotor bolt
1

• washer
NOTE:

While holding the generator rotor
2
with the rotor holding tool
3
, loosen the
generator rotor bolt.
Rotor holding tool
90890-01235
3. Remove:
• generator rotor
1
(with the flywheel puller
2
and rotor
holding tool
3
)
Flywheel puller
90890-01080
EB410700
INSTALLING THE GENERATOR
1. Apply:
• sealant
(onto the stator coil assembly lead
grommet)
2. Install:
• generator rotor
• washer
• generator rotor bolt
WARNINGWARNING

Always use a new generator rotor bolt.
ACHTUNG:CAUTION:

• Clean the tapered portion of the crank-
shaft and the generator rotor hub with
lacquer thinner.
• Lubricate the generator rotor bolt
threads with engine oil.
Yamaha bond No. 1215
90890-85505

ENG

4 - 35
PICKUP COIL
PICKUP COIL
T R..45 Nm (4.5 m • kg, 32 ft • Ib)
T R..12 Nm (1.2 m • kg, 8.7 ft • Ib)
T R..4 Nm (0.4 m • kg, 2.9 ft • Ib)
T R..15 Nm (1.5 m • kg, 11 ft • Ib)
E
LTLT
LTLT
1
(6)23
4
5 64 7
New

Order Job/Part Q’ty Remarks
Removing the pickup coil and
pickup coil rotor
Remove the parts in the order listed.
Fuel tank Refer to “FUEL TANK AND AIR FIL-
TER” in chapter 3.
Bottom cowling and front cowling Refer to “COWLINGS” in chapter 3.
Engine oil Drain.
Refer to “CHANGING THE ENGINE
OIL” in chapter 3.
Generator rotor cover Refer to “GENERATOR”.
1 Pickup coil lead holder 1
2 Pickup coil rotor cover 1
3 Pickup coil rotor cover gasket 1
4 Dowel pin 2

4 - 37
ENG

PICKUP COIL
REMOVING THE PICKUP COIL ROTOR
1. Remove:
• pickup coil lead holder
1

• pickup coil rotor cover
2

NOTE:

Loosen each bolt 1/4 of a turn at a time,
in stages and in a crisscross pattern.
After all of the bolts are fully loosened,
remove them.
2
2
1

1

2. Remove:
• pickup coil rotor bolt
1

• washer
• pickup coil rotor
2

NOTE:

While holding the generator rotor
3
with the rotor holding tool
4, loosen the
pickup coil rotor bolt.
Rotor holding tool
90890-01235
2
2

1

1

INSTALLING THE PICKUP COIL ROTOR
1. Install:
• pickup coil rotor 1
• washer
• pickup coil rotor bolt
NOTE:
When installing the pickup coil rotor,
align the groove 2 in the crankshaft
sprocket with the projection a in the
pickup coil rotor.
ACHTUNG:CAUTION:
Lubricate the pickup coil rotor bolt
threads with engine oil.
1
1

2

2
a
a