relay YAMAHA YZF-R7 1999 Owners Manual

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 - 23
SPEC
EB202010
CHASSIS LUBRICATION POINTS AND LUBRICANT TYPES
Lubrication point Lubricant
Steering bearings and bearing races (upper and lower)
LS
Front wheel oil seal (right and left)LS
Rear wheel oil sealLS
Rear wheel drive hub oil sealLS
Rear wheel drive hub mating surfaceLS
Rear brake pedalLS
Sidestand pivoting point and metal-to-metal moving partsLS
Throttle grip inner surfaceLS
Brake lever pivoting point and metal-to-metal moving partsLS
Clutch lever pivoting point and metal-to-metal moving partsLS
Pivot shaftM
Connecting arm bearing (left and right)M
Spacer (relay arm and connecting arm)M
Oil seal (relay arm and connecting arm)M
LUBRICATION POINTS AND LUBRICANT TYPES

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

3 - 2
CHK
ADJ

PERIODIC MAINTENANCE AND LUBRICATION
INTERVALS
*
Since these items require special tools, data and technical skills, they should be serviced by a
Yamaha dealer.
NOTE:

• The air filter element needs more frequent service if you are riding in unusually wet or
dusty areas.
• Hydraulic brake system
– Replace the brake fluid or clutch fluid after disassembling the master cylinder, caliper cyl-
inder or release cylinder.
– Check the brake fluid or clutch fluid level and add fluid as required.
– Replace the master cylinder, caliper cylinder and release cylinder oil seals every two
years.
– Replace the brake hoses and clutch hose every four years, or if cracked or damaged.
15
*
Chassis fasteners
• Make sure that all nuts, bolts and screws are properly
tightened.
• Tighten if necessary.
ÖÖ
16 Sidestand
• Check operation.
• Lubricate and repair if necessary.
ÖÖ
17
*
Sidestand switch
• Check operation.
• Replace if necessary.
ÖÖÖ
18
*
Front fork
• Check operation and for oil leakage.
• Correct accordingly.
ÖÖ
19
*
Rear shock
absorber assembly
• Check operation and shock absorber for oil leakage.
• Replace shock absorber assembly if necessary.
ÖÖ
20
*
Rear suspension
relay arm and con-
necting arm pivot-
ing points
• Check operation.
• Lubricate with lithium soap base grease every 24,000
km or 24 months (whichever comes first).
ÖÖ
21
*
Electronic fuel
injection system
• Check engine idling speed, synchronization and
starter operation.
• Adjust if necessary.
ÖÖÖ
22 Engine oil
• Check oil level and vehicle for oil leakage.
• Correct if necessary.
• Change. (Warm engine before draining.)
ÖÖÖ
23Engine oil filter
cartridge
• Replace.
ÖÖ
24
*
Cooling system
• Check coolant level and vehicle for coolant leakage.
• Correct if necessary.
• Change coolant every 24,000 km 24 months (which-
ever comes first).
ÖÖ
No. ITEM CHECKS AND MAINTENANCE JOBSINITIAL
1,000 km EVERY
6,000 km or
6 months
(whichever
comes first)12,000 km or
12 months
(whichever
comes first)
3

7 - 76
CHAS
EB706000
REAR SHOCK ABSORBER ASSEMBLY
Order Job/Part Q’ty Remarks
Removing the rear shock absorber
assemblyRemove the parts in the order listed.
1 Bolt 1
2 Self-locking nut/bolt 1/1
3 Self-locking nut/bolt 2/2
4 Self-locking nut/bolt 1/1
5 Rear shock absorber assembly 1
6 Self-locking nut/bolt 1/1
7 Connecting arm 2
8 Spacer/oil seal/bearing2/4/2
9 Sidestand 1
10 Self-locking nut/bolt/spacer1/1/1
11 Relay arm 1
12 Spacer/oil seal/bearing3/6/3
For installation, reverse the removal
procedure.
REAR SHOCK ABSORBER ASSEMBLY

7 - 79
CHAS
CHECKING THE RELAY ARM AND
CONNECTING ARM
1. Check:
• relay arm 1
• connecting arm 2
Damage/wear ® Replace.
• bearings
• oil seals
Damage/pitting ® Replace.
• spacers
Damage/scratches ® Replace.
1
1
2
2

2

2

EB706701
INSTALLING THE REAR SHOCK ABSORBER
ASSEMBLY
1. Lubricate:
• bearings
• oil seals
• spacers
2. Install:
• relay arm
• connecting arms
• rear shock absorber assembly
NOTE:
When installing the rear shock absorber
assembly, lift up the swingarm.
3. Tighten:
• relay arm-to-frame nut
• relay arm-to-connecting arm nut
• connecting arm-to-swingarm nut
• rear shock absorber assembly upper nut
• rear shock absorber assembly lower nut
Recommended lubricant
Molybdenum disulfide grease
T R..40 Nm (4.0 m · kg, 29 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..40 Nm (4.0 m · kg, 29 ft · lb)
T R..40 Nm (4.0 m · kg, 29 ft · lb)
REAR SHOCK ABSORBER ASSEMBLY

8 - 1
–+ELEC

ELECTRICAL COMPONENTS
EB800000
ELECTRICAL
ELECTRICAL COMPONENTS
1
Wire harness
2
Main switch
3
Front brake light switch
4
Ignition coils
5
Clutch switch
6
Throttle position sensor
7
Intake air temperature sensor
8
Intake air pressure sensor
9
Atmospheric pressure sensor
0
Turn signal relay
A
Relay unit
B
ECU
C
CDI unit
D
Fuse box
E
Fall detection switch
F
Starter relay
G
Main fuse
H
Main relay
I
Battery
J
Rectifier/regulator
K
Rear brake light switch
L
Neutral switch
M
Speed sensor
N
Sidestand switch
O
Stator coil assembly
P
Oil level switch
Q
Pickup coil
R
Radiator fan
S
Horn
T
Coolant temperature
sender
U
Thermo switch
V
Camshaft sensor
8