1999 YAMAHA YZF-R7 radiator cap

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DESCRIPTION
DESCRIPTION
Left view
Right view
1. Front fork compression damping force adjusting screw
2. Front fork rebound damping force adjusting screw
3. Front fork spring preload adjusting bolt
4. Air filter
5. Starter (choke) “ “
6. Shift pedal
7. Rear shock absorber spring preload adjusting ring
8. Rear shock absorber compression damping force adjusting screw
9. Rear shock absorber rebound damping force adjusting screw
10. Fuses
11. Rear brake resorvoir
12. Rear brake pedal
13. Radiator cap and coolant reservoir tank cap
14. Engine oil filter
14
56
78
9
2,3
10
11
1213 14

1

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TROUBLESHOOTING CHART
5. Engine overheatingEW000070
WARNING
Do not remove the radiator cap when the engine and radiator are hot. Scalding hot fluid and steam may be blown out
under pressure, which could cause serious injury. Open the radiator cap as follows. Wait until the engine has
cooled. Remove the radiator cap stopper by removing the screw. Place a thick rag like a towel over the radiator cap
and slowly rotate the cap counterclockwise to the detent. This procedure allows any residual pressure to escape.
When the hissing sound has stopped, press down on the cap while turning counterclockwise and remove it.
NOTE:
If it is difficult to get the recommended coolant, tap water can be temporarily used, provided that it is changed to the recom-
mended coolant as soon as possible.
Wait until the
engine has cooled.Check the coolant level in the
reservoir tank and/or radiator.
Level is OK.
Level is low, check the
cooling system for leakage.
No
leakage.
Leakage.Ask a Yamaha dealer to inspect
and repair the cooling system.
Add coolant. (See NOTE.)
Restart the engine. If the engine overheats again, ask a
Yamaha dealer to inspect and repair the cooling system.

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SPECIAL TOOLS
EB104000
SPECIAL TOOLS
The following special tools are necessary for complete and accurate tune-up and assembly.
Use only the appropriate special tools as this will help prevent damage caused by the use of
inappropriate tools or improvised techniques.
When placing an order, refer to the list provided below to avoid any mistakes.
Tool No. Tool name/Function Illustration
90890-01080Flywheel puller
This tool is used to remove the generator
rotor.
90890-01235Rotor holding tool
This tool is used to hold the generator
rotor when removing or installing the gen-
erator rotor bolt or pickup coil rotor bolt.
90890-01286Drive chain cutter
This tool is used to remove the drive
chain.
90890-01304Piston pin puller
This tool is used to remove the piston
pins.
Radiator cap
tester
90890-01325
Adapter
90890-01352Radiator cap tester
Adapter
These tools are used to check the cooling
system.
90890-01403Steering nut wrench
This tool is used to loosen or tighten the
steering stem ring nuts.
90890-01426Oil filter wrench
This tool is needed to loosen or tighten
the oil filter cartridge.
90890-01434Rod holder
This tool is used to support the damper
adjusting rod.

ENGINE SPECIFICATIONS
SPEC

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Oil filter
Oil filter type Cartridge (paper) ----
Bypass valve opening pressure 180 ~ 220 kPa
(1.8 ~ 2.2 kgf/cm
2

, 25.6 ~ 31.3 psi)----
Oil pump

Oil pump type Trochoidal ----
Inner rotor-to-outer rotor tip clear-
ance0.09 ~ 0.15 mm (0.004 ~ 0.006 in) ----
Outer rotor-to-oil pump housing
clearance0.03 ~ 0.08 mm (0.001 ~ 0.003 in) ----
Cooling system
Radiator capacity 2.75 L (2.42 Imp qt, 2.91 US qt)
Radiator cap opening pressure 95 ~ 125 kPa
(0.95 ~ 1.25 kgf/cm
2

, 13.1 ~ 17.8 psi)----
Upper radiator core
Width 414 mm (16.3 in) ----
Height 248 mm (9.76 in) ----
Depth 24 mm (0.94 in) ----
Lower radiator core
Width 211 mm (8.31 in) ----
Height 158 mm (6.22 in) ----
Depth 24 mm (0.94 in) ----
Coolant reservoir
Capacity 0.6 L (0.53 Imp qt, 0.63 US qt) ----
Water pump
Water pump type Single-suction centrifugal pump ----
Reduction ratio 88/47
´
28/25 (2.097) ----
Maximum impeller shaft tilt ---- 0.15 mm
(0.006 in)
Starting system type
Electric starter
Spark plugs
Model (manufacturer)
´
quantity R0256R-10 (NGK)
´
4 ----
Spark plug gap 0.7 ~ 0.8 mm (0.028 ~ 0.031 in) ----
Cylinder head
Maximum warpage ---- 0.06 mm
(0.0024 in) Item Standard Limit

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CHK
ADJ
CHANGING THE COOLANT
EB303240
CHANGING THE COOLANT
1. Remove:
• bottom cowling
• front cowling
Refer to “COWLINGS”.
2. Remove:
• coolant reservoir bolts 1
• coolant reservoir cap 2
NOTE:
When draining the coolant from the
coolant reservoir, be sure to tilt the res-
ervoir so that coolant cannot flow
through the coolant reservoir breather
hose 3.
3. Drain:
• coolant
(from the coolant reservoir)
4. Install:
• coolant reservoir bolts
2
2

1

1

5. Remove:
• radiator cap 1
WARNINGWARNING
A hot radiator is under pressure. There-
fore, do not remove the radiator cap
when the engine is hot. Scalding hot
fluid and steam may be blown out,
which could cause serious injury. When
the engine has cooled, open the radiator
cap as follows:
Place a thick rag or a towel over the
radiator cap and slowly turn the radia-
tor cap counterclockwise toward the
detent to allow any residual pressure to
escape. When the hissing sound has
stopped, turn the radiator cap counter-
clockwise while pressing down on it
and then remove it.
1
1

6. Remove:
• coolant drain bolt 1
(along with the copper washer)
7. Drain:
• coolant

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CHK
ADJ
CHANGING THE COOLANT
ACHTUNG:CAUTION:
• Adding water instead of coolant low-
ers the antifreeze content of the cool-
ant. If water is used instead of coolant,
check, and if necessary, correct the
antifreeze concentration of the cool-
ant.
• Use only distilled water. However,
soft water may be used if distilled
water is not available.
• If coolant comes into contact with
painted surfaces, immediately wash
them with water.
• Do not mix different types of anti-
freeze.
11.Install:
• radiator cap
12.Fill:
• coolant reservoir
(with the recommended coolant to the
maximum level mark a)
13.Install:
• coolant reservoir cap
14.Start the engine, warm it up for several
minutes, and then turn it off.
aa
15.Check:
• coolant level
Refer to “CHECKING THE COOLANT
LEVEL”.
NOTE:
Before checking the coolant level, wait a
few minutes until the coolant has set-
tled.
16.Install:
• front cowling
• bottom cowling
Refer to “COWLINGS”.

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COOL

RADIATOR AND THERMOSTAT
EB500010
CHECKING THE RADIATOR
1. Check:
• radiator fins
Obstruction
®
Clean.
Apply compressed air to the rear of the
radiator.
Damage
®
Repair or replace.
NOTE:

Straighten any flattened fins with a thin,
flat-head screwdriver.
2. Check:
• radiator hoses
Cracks/damage
®
Replace.
3. Measure:
• radiator cap opening pressure
Below the specified pressure
®
Replace the radiator cap.
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. Install the radiator cap tester
1
and
adapter
2
onto the radiator cap
3
.
b. Apply the specified pressure for ten
seconds and make sure that there is
no drop in pressure.
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
Radiator cap opening pressure
95 ~ 125 kPa
(0.95 ~ 1.25 kg/cm
2

,
3.51 ~ 7.78 psi)
Radiator cap tester
90890-01325
Adapter
90890-01352
4. Check:
• radiator fan
Damage
®
Replace.
Malfunction
®
Check and repair.
Refer to “COOLING SYSTEM” in chap-
ter 8.

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COOL

RADIATOR AND THERMOSTAT
INSTALLING THE THERMOSTAT
ASSEMBLY AND RADIATOR
1. Fill:
• cooling system
(with the specified amount of the rec-
ommended coolant)
Refer to “CHANGING THE COOLANT”
in chapter 3.
2. Check:
• cooling system
Leaks
®
Repair or replace any faulty
part.
3. Measure:
• radiator cap opening pressure
Below the specified pressure
®
Replace the radiator cap.
Refer to “CHECKING THE RADIATOR”.