1999 YAMAHA YZF-R7 transmission

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 - 4
INSTRUMENT AND CONTROL FUNCTIONS
INSTRUMENT AND CONTROL FUNCTIONS
EAU00029
Main switch/Steering lock
The main switch controls the ignition
and lighting systems. Its operation is
described below.
EAU00036
ON
Electrical circuits are switched on. The
engine can be started. The key cannot
be removed in this position.
EAU00038
OFF
All electrical circuits are switched off.
The key can be removed in this posi-
tion.
EAU00040
LOCK
The steering is locked in this position
and all electrical circuits are switched
off. The key can be removed in this po-
sition. To lock the steering, turn the
handlebars all the way to the left. While
pushing the key into the main switch,
turn it from “OFF” to “LOCK” and re-
move it. To release the lock, turn the
key to “OFF” while pushing.
1. Push
2. Turn
EW000016
WARNING

Never turn the key to “OFF” or
“LOCK” when the motorcycle is
moving. The electrical circuits will
be switched off which may result in
loss of control or an accident. Be
sure the motorcycle is stopped be-
fore turning the key to “OFF” or
“LOCK”.
EAU01574
(Parking)
The steering is locked in this posi-
tion, and the taillights and auxiliary
lights come on, but all other circuits
are off. The key can be removed in
this position.
To use the parking position, first
lock the steering, then turn the key
to “ ”. Do not use this position for
an extended length of time as the
battery may discharge.
1.
Neutral indicator light “ ”
2. High beam indicator light “ ”
3. Turn indicator light “ ”
4. Fuel indicator light “ ”
EAU00056
Indicator lights
EAU00061
Neutral indicator light “ ”
This indicator comes on when the
transmission is in neutral.
EAU00063
High beam indicator light “ ”
This indicator comes on when the
headlight high beam is used.
EAU00057
Turn indicator light “ ”
This indicator flashes when the turn
switch is moved to the left or right.
EAU01154
Fuel indicator light “ ”
When the fuel level drops below
approximately 4.8 L, this light will
come on. When this light comes
on, fill the tank at the first opportuni-
ty. This light circuit can be checked
by the procedure on page 1-7.
If there is a shortcircuit or disconti-
nuity at the thermistor, the fuel indi-
cator light will flash 8 times and
then stay off for 3 seconds repeat-
edly.

1 - 10
INSTRUMENT AND CONTROL FUNCTIONS
1 1

1. Shift pedal
EAU00157
Shift pedal
This motorcycle is equipped with a con-
stant-mesh 6-speed transmission.
The shift pedal is located on the left
side of the engine and is used in com-
bination with the clutch when shifting.
1. Lever position adjusting dial
2. Arrow mark
a. Lever distance
EAU00161
Front brake lever
The front brake lever is located on the
right handlebar and is equipped with a
brake lever adjusting dial.
To activate the front brake, pull the le-
ver toward the handlebar.
To adjust the front brake lever position,
turn the brake lever adjusting dial while
pulling the lever forward. Make sure the
setting on the brake lever adjusting dial
is aligned with the arrow mark.
1 1
1. Rear brake pedalEAU00162
Rear brake pedal
The rear brake pedal is on the right
side of the motorcycle. Press down on
the brake pedal to apply the rear brake.
1. OpenEAU00172
Fuel tank cap
To open
Insert the key and turn it 1/4 turn clock-
wise. The lock will be released and the
cap can be opened.
To close
Push the tank cap into position with the
key inserted. To remove the key, turn it
counterclockwise to the original posi-
tion.
1 1NOTE:
This tank cap cannot be closed unless
the key is in the lock. The key cannot
be removed if the cap is not locked
properly.
EW000023
WARNING
Be sure the cap is properly installed
and locked in place before riding the
motorcycle.
1. Filler tube
2. Fuel level
EAU01183
Fuel
Make sure there is sufficient fuel in the
tank. Fill the fuel tank to the bottom of
the filler tube as shown in the illustra-
tion.
EW000130
WARNING
Do not overfill the fuel tank. Avoid
spilling fuel on the hot engine. Do
not fill the fuel tank above the bot-
tom of the filler tube or it may over-
flow when the fuel heats up later and
expands.

1 - 11
INSTRUMENT AND CONTROL FUNCTIONS
EAU00185
CAUTION:
Always wipe off spilled fuel immedi-
ately with a dry and clean soft cloth.
Fuel may deteriorate painted surfac-
es or plastic parts.
EAU00191
NOTE:
If knocking or pinging occurs, use a dif-
ferent brand of gasoline or higher oc-
tane grade.Recommended fuel:
Premium unleaded gasoline
with a research octane
number of 95 or higher.
Fuel tank capacity:
Total:
23 L
Reserve:
4.8 L
1 1
a a b b
1. Starter (choke) “ ”EAU00210
Starter (choke) “ ”
Starting a cold engine requires a richer
air-fuel mixture. A separate starter cir-
cuit supplies this mixture.
Move in direction
a to turn on the
starter (choke).
Move in direction
b to turn off the
starter (choke).
EAU00331
Sidestand/clutch switch
operation check
Check the operation of the sidestand
switch and clutch switch against the in-
formation below.
COPY CD-11ECD-11E
TRANSMISSION IS IN GEAR AND
SIDESTAND IS UP.
PULL IN CLUTCH LEVER AND
PUSH THE START SWITCH.
ENGINE WILL START.
SIDESTAND IS DOWN.
CLUTCH SWITCH IS OK.
TURN THE MAIN SWITCH TO “ON”
AND THE ENGINE STOP SWITCH TO
“”.
CD-11E
EW000045
WARNING
If improper operation is noted, con-
sult a Yamaha dealer immediately.
ENGINE WILL STALL.
SIDESTAND SWITCH IS OK.

1 - 12
OPERATION AND IMPORTANT RIDING POINTS
OPERATION AND IMPORTANT RIDING POINTS
EAU00373
WARNING
lBefore riding this motorcycle,
become thoroughly familiar
with all operating controls and
their functions. Consult a
Yamaha dealer regarding any
control or function that you do
not thoroughly understand.
lNever start your engine or let it
run for any length of time in a
closed area. The exhaust fumes
are poisonous and can cause
loss of consciousness and
death within a short time. Al-
ways operate your motorcycle
in an area with adequate venti-
lation.
lBefore starting out, always be
sure the sidestand is up. Fail-
ure to retract the sidestand
completely can result in a seri-
ous accident when you try to
turn a corner.
EAU01382*
Starting the engine
NOTE:
This motorcycle is equipped with an ig-
nition circuit cut-off system.
The engine can be started only under
one of the following conditions:
lThe transmission is in neutral.
lThe sidestand is up, the transmis-
sion is in gear and the clutch is
disengaged.
The motorcycle must not be ridden
when the sidestand is down.
EW000054
WARNING
Before going through the following
steps, check the function of the sid-
estand switch and clutch switch.
(Refer to page 1-11.)
COPY CF-28ECF-28E
TURN THE MAIN SWITCH TO “ON” AND THE
ENGINE STOP SWITCH TO “ ”.
IF TRANSMISSION IS IN NEUTRAL AND
SIDESTAND IS DOWN,
PUSH THE START SWITCH.
ENGINE WILL START.
RETRACT SIDESTAND AND PUT
TRANSMISSION IN GEAR.
IF TRANSMISSION IS IN GEAR AND
SIDESTAND IS UP,
PULL IN THE CLUTCH LEVER AND PUSH START
SWITCH. ENGINE WILL START.
MOTORCYCLE CAN BE RIDDEN.MOTORCYCLE CAN BE RIDDEN.

1 - 13
OPERATION AND IMPORTANT RIDING POINTS
1. Turn the main switch to “ON” and
the engine stop switch to “ ”.
ECA00005
CAUTION:
The warning light and fuel indicator
light should come on for a few sec-
onds and then go off. If an indicator
light does not go off, refer to the cor-
responding indicator light circuit
check in the “INSTRUMENT AND
CONTROL FUNCTIONS” section.
2. Shift the transmission into neutral.
NOTE:
When the transmission is in neutral, the
neutral indicator light should be on. If
the light does not come on, ask a
Yamaha dealer to inspect it.
3. Turn on the starter (choke) and
completely close the throttle grip.
4. Start the engine by pushing the
start switch.
NOTE:
If the engine fails to start, release the
start switch, wait a few seconds, then
try again. Each attempt should be as
short as possible to preserve the bat-
tery. Do not crank the engine more
than 10 seconds on any one attempt.5. After starting the engine, move
the starter (choke) to the halfway
position.
NOTE:
For maximum engine life, never accel-
erate hard with a cold engine!
6. After the engine is warm, turn off
the starter (choke) completely.
NOTE:
The engine is warm when it responds
normally to the throttle with the starter
(choke) turned off.
EAU01258
Starting a warm engine
The starter (choke) is not required
when the engine is warm.
EC000046
CAUTION:
See the “Engine break-in” section
prior to operating the motorcycle for
the first time.
1 16
65
5
4 4
3 3
N N2 2
1 1
1. Shift pedal
N. Neutral
EAU00423
Shifting
The transmission lets you control the
amount of power you have available at
a given speed for starting, accelerating,
climbing hills, etc. The use of the shift
pedal is shown in the illustration.
To shift into neutral, depress the shift
pedal repeatedly until it reaches the
end of its travel, then raise the pedal
slightly.
EC000048
CAUTION:
lDo not coast for long periods
with the engine off, and do not
tow the motorcycle a long dis-
tance. Even with gears in neu-
tral, the transmission is only
properly lubricated when the
engine is running. Inadequate
lubrication may damage the
transmission.
lAlways use the clutch when
changing gears. The engine,
transmission, and driveline are
not designed to withstand the
shock of forced shifting and
can be damaged by shifting
without using the clutch.

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

2 - 22
SPEC
EB202000
LUBRICATION POINTS AND LUBRICANT TYPES
ENGINE LUBRICATION POINTS AND LUBRICANT TYPES
Lubrication point Lubricant
Oil seal lips
LS
O-ringsLS
BearingsE
Crankshaft pinsE
Piston surfacesE
Piston pinsE
Connecting rod bolts and nuts MOLYKOTE® G-n paste
Crankshaft journals
E
Camshaft lobesM
Camshaft journalsM
Valve stems (intake and exhaust)M
Valve stem ends (intake and exhaust)E
Water pump impeller shaftE
Oil pump rotors (inner and outer)E
Oil pump housing E
Oil strainer E
Starter clutch idle gear inner surfaceE
Starter clutch assemblyE
Primary driven gearE
Transmission gears (wheel and pinion)M
Main axle and drive axleM
Shift drumE
Shift forks and shift fork guide barsE
Shift shaft E
Shift shaft bossLS
Cylinder head cover mating surfaceYamaha bond
No. 1215
Cylinder head coverYamaha bond
No. 1215
Crankcase mating surfaceYamaha bond
No. 1215
Clutch cover (crankcase mating surface)Yamaha bond
No. 1215
Generator rotor cover (crankcase mating surface)Yamaha bond
No. 1215
Pickup coil rotor cover (crankcase mating surface)Yamaha bond
No. 1215
LUBRICATION POINTS AND LUBRICANT TYPES