1999 YAMAHA YZF-R7 fuel pump

CHAPTER 3
PERIODIC CHECKS AND
ADJUSTMENTS
INTRODUCTION ....................................... 3-1
PERIODIC MAINTENANCE AND
LUBRICATION INTERVALS ...................... 3-1
GENERAL MAINTENANCE AND
LUBRICATION CHART .............................. 3-2
FUEL TANK AND AIR FILTER .................. 3-4
COWLINGS ............................................... 3-6
ENGINE ..................................................... 3-9
CHASSIS ................................................. 3-36
ELECTRICAL SYSTEM ............................ 3-55
CHAPTER 4
OVERHAULING THE ENGINE
ENGINE ..................................................... 4-1
CAMSHAFTS ............................................. 4-8
CYLINDER HEAD .................................... 4-18
VALVES AND VALVE SPRINGS ............ 4-21
GENERATOR ........................................... 4-32
PICKUP COIL ........................................... 4-35
CLUTCH ................................................... 4-39
SHIFT SHAFT .......................................... 4-48
OIL PAN AND OIL PUMP ....................... 4-50
CRANKCASE ........................................... 4-56
CONNECTING RODS AND
PISTONS ................................................. 4-63
CRANKSHAFT ......................................... 4-74
TRANSMISSION ..................................... 4-79
CHAPTER 5
COOLING SYSTEM
RADIATOR AND THERMOSTAT .............. 5-1
RADIATOR AND THERMOSTAT .............. 5-3
OIL COOLER .............................................. 5-9
WATER PUMP ......................................... 5-12

1 - 25
SPECIAL TOOLS
Compression
gauge
90890-03081
Adapter
90890-04136Compression gauge
Adapter
These tools are used to measure engine
compression.
90890-03112Pocket tester
This tool is used to check the electrical
system.
Pressure
gauge
90890-03153
Adapter
90890-03151Pressure gauge
Adapter
These tools are used to measure the fuel
pressure.
90890-03149Test coupler adapter
This tool is used to check the electrical
control system.
90890-03171Co, diagnosis switch box
This tool is used to check the electrical
control system.
Valve spring com-
pressor
90890-04019
Attachment
90890-04108
90890-04114
Valve spring compressor
Attachment
These tools are used to remove or install
the valve assemblies.
Middle driven shaft
bearing driver
90890-04058
Mechanical seal
installer
90890-04078
Middle driven shaft bearing driver
Mechanical seal installer
These tools are used to install the water
pump seal.
90890-04086Clutch holding tool
This tool is used to hold the clutch boss
when removing or installing the clutch
boss nut.
90890-04111Valve guide remover
This tool is used to remove or install the
valve guides.
Tool No. Tool name/Function Illustration
MODEUP
YES/ON
DOWN
NO/OFF

ENGINE SPECIFICATIONS
SPEC

2 - 10
Clutch plates
Thickness 1.5 ~ 1.7 mm (0.059 ~ 0.067 in) ----
Plate quantity 8 ----
Maximum warpage ---- 0.1 mm
(0.004 in)
Clutch springs
Free length 7.1 mm (0.280 in) ----
Spring quantity 1 spring per valve ----
Transmission
Transmission type Constant mesh, 6-speed ----
Primary reduction system Spur gear ----
Primary reduction ratio 88/47 (1.872) ----
Secondary reduction system Chain drive ----
Secondary reduction ratio 43/17 (2.529) ----
Operation Left-foot operation ----
Gear ratios
1st gear 38/17 (2.235) ----
2nd gear 36/19 (1.895) ----
3rd gear 35/21 (1.667) ----
4th gear 33/23 (1.435) ----
5th gear 31/24 (1.292) ----
6th gear 27/23 (1.174) ----
Maximum main axle runout ---- 0.08 mm
(0.003 in)
Maximum drive axle runout ---- 0.08 mm
(0.003 in)
Shifting mechanism
Shift mechanism type Shift drum ----
Maximum shift fork guide bar
bending ---- 0.05 mm
(0.002 in)
Installed shift rod length 294 mm (11.57 in) ----
Air filter type
Dry element ----
Fuel pump
Pump type Electrical ----
Model (manufacturer) 5FL (MITSUBISHI) ----
Output pressure 450 ~ 600 kPa
(4.5 ~ 6.0 kgf/cm
2

, 64 ~ 85 psi)----
Throttle bodies
ID mark 5FL1 ----
Throttle valve #100 ----
Intake vacuum pressure 15.8 ~ 18.4 kPa
(120 ~ 140 mmHg, 4.72 ~ 5.51 in Hg)----
Throttle cable free play (at the
flange of the throttle grip)3 ~ 5 mm (0.12 ~ 0.20 in) ---- Item Standard Limit

ELECTRICAL SPECIFICATIONSSPEC
2 - 16
Electric starting system
System type Constant mesh ----
Starter motor
Model (manufacturer) SM-14 (MITSUBA) ----
Power output 0.6 kW ----
Armature coil resistance 0.0015 ~ 0.0025 W----
Brushes
Overall length 10 mm (0.40 in) 3.5 mm
(0.14 in)
Spring force 7.16 ~ 9.52 N
(730 ~ 971 gf, 25.8 ~ 34.3 oz)----
Commutator resistance 0.025 ~ 0.035 W----
Commutator diameter 28 mm (1.10 in) 27 mm
(1.06 in)
Mica undercut 0.7 mm (0.03 in) ----
Starter relay
Model (manufacturer) MS5F-631 (JIDECO) ----
Amperage 180 A ----
Coil resistance 4.18 ~ 4.62 W ----
Horn
Horn type Plain ----
Model (manufacturer) ´ quantity YF-12 (NIKKO) ´ 1 ----
Max. amperage 3 A ----
Turn signal relay
Relay type Full-transistor ----
Model (manufacturer) FE246BH (DENSO) ----
Self-cancelling device built-in No ----
Turn signal blinking frequency 75 ~ 95 cycles/min. ----
Wattage 21 W ´ 2 + 3.4 W ----
Oil level switch model (manufac-
turer)071380-0480 (DENSO) ----
Fuel pump relay model (manufac-
turer)G8R-30Y-J (OMRON) ----
Thermo switch model (manufac-
turer)5EB (NIPPON THERMOSTAT) ----
Fuses (amperage ´ quantity)
Main fuse 30 A ´ 1 ----
Headlight fuse 20 A ´ 1 ----
Signaling system fuse 20 A ´ 1 ----
EFI fuse 20 A ´ 1 ----
ECU fuse 7.5 A ´ 1 ----
Radiator fan fuse 7.5 A ´ 1 ----
Backup fuse (odometer) 7.5 A ´ 1 ---- Item Standard Limit

2 - 21
SPEC
CHASSIS TIGHTENING TORQUES
HINWEIS:NOTE:
1.First, tighten the ring nut to approximately 18 Nm (1.8 m • kg, 13 ft • lb) with a torque
wrench, then loosen the ring nut completely.
2.Retighten the ring nut to specification.Item Thread sizeTightening torque
Remarks
Nm m·kgf ft·lb
Upper bracket pinch bolts M8 26 2.6 19
Steering stem nut M28 115 11.5 85
Handlebar pinch bolts M6 13 1.3 9.4
Lower ring nut M30 9 0.9 6.5 See NOTE.
Lower bracket pinch bolts M6 11 1.1 8.0
Front brake hose union bolts M10 30 3.0 22
Front brake master cylinder M6 13 1.3 9.4
Engine mounting
Spacer bolts M16 18 1.8 13
Left front mounting bolts M10 40 4.0 29
Right front mounting bolts M10 40 4.0 29
Rear mounting bolts M10 55 5.5 40
Pinch bolts M8 17 1.7 12
Exhaust pipe bracket M8 24 2.4 17
Pivot shaft nut M18 125 12.5 90
Connecting arms M10 40 4.0 29
Relay arm and connecting arms M10 40 4.0 29
Relay arm M10 40 4.0 29
Rear shock absorber and relay arm M10 40 4.0 29
Rear shock absorber assembly M10 40 4.0 29
Fuel pump and fuel tank M5 4 0.4 2.9
Coolant reservoir and radiator M6 5 0.5 3.6
Rider footrest bracket M8 28 2.8 20
Rear master cylinder M8 23 2.3 17
Rear brake hose union bolts M10 30 3.0 22
Sidestand bracket M8 26 2.6 19
Front wheel axle M20 79 7.9 57
Rear wheel axle M24 150 15.0 110
Rear wheel axle nut M24 45 4.5 32
Front brake caliper and front fork M10 40 4.0 29
Rear brake caliper and bracket M10 40 4.0 29
Brake disc and wheel M6 18 1.8 13
Rear wheel sprocket and rear wheel
drive hubM10 69 6.9 50
Brake caliper and bleed screw M8 6 0.6 4.3
Pinch bolt (front wheel axle) M8 23 2.3 17
TIGHTENING TORQUES

2 - 28
SPEC
1Left handlebar switch lead
2Starter cable
3Main relay
4Speed sensor
5Throttle stop screw
6Sidestand switch lead
7Oil level switch lead
8Main switch lead
9Headlight and meter sub-wire har-
ness coupler0Horn lead
AHeadlight and meter sub-wire harness lead
BThrottle cable
CClutch hose
DWire harness (to headlight and meter sub-wire harness)
EWire harness
FFuel tank overflow hose
GWater pump breather hose
HCoolant reservoir breather hose
IAir filter case breather hose
CABLE ROUTING

2 - 29
SPEC
JFuel tank breather hose
KCDI unit
LFall detection switch
MFuse box
NRelay unit
Align the portions of the main
switch lead and left handle-
bar switch lead marked with
white tape with the radiator
bracket at the frame.õFasten the starter cable and wire harness with a plastic band.
‚Fasten the oil level switch lead, speed sensor lead, sidestand
switch lead and stator coil assembly lead with a plastic band.
ëFasten the air filter breather hose, fuel tank overflow hose, clutch
hose and fuel tank breather hose with a plastic band.
ä20 mm (0.79 in)
ìRoute the sidestand switch lead behind the water pump breather
hose.
íRoute the oil level switch lead to the outside of the water pump
breather hose guide.
CABLE ROUTING

2 - 30
SPEC
1Ignition coil
2Throttle position sensor coupler
3Camshaft sensor
4Injector 1 coupler
5Starter motor
6Fuel tank overflow hose
7Fuel pump coupler
8Rectifier/regurator
9Battery
0Turn signal relayAECU
BFuse box
CFall detection switch
DStarter relay
EMain relay
FThrottle stop screw cable
GFuel tank breather hose
HAir filter case breather hose
IIntake air temperature sensor coupler
JInjector 2 sub-lead
CABLE ROUTING