YAMAHA YZF-R7 1999 Owners Manual

3 - 32
CHK
ADJ
CHECKING THE COOLING SYSTEM
EB303230
CHECKING THE COOLING SYSTEM
1. Remove:
• bottom cowling
• front cowling
Refer to “COWLINGS”.
2. Check:
• upper radiator 1
• lower radiator 2
• radiator inlet hose 3
• radiator outlet hose 4
• radiator outlet pipe 5
• radiator joint hose 6
• oil cooler 7
• oil cooler inlet hose 8
• oil cooler outlet hose 9
• water jacket joint inlet hose 0
• water pump inlet pipe A
• water pump outlet pipe B
Cracks/damage ® Replace.
Refer to “COOLING SYSTEM” in chap-
ter 5.
3. Install:
• front cowling
• bottom cowling
Refer to “COWLINGS”.

3 - 33
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

3 - 34
CHK
ADJ
CHANGING THE COOLANT
8. Check:
• copper washer 1
• coolant drain bolt 2
Damage ® Replace.
9. Install:
• coolant drain bolt
T R..7 Nm (0.7 m · kg, 5.1 ft · lb)
10.Fill:
• cooling system
(with the specified amount of the rec-
ommended coolant)
Recommended antifreeze
High-quality ethylene glycol
antifreeze containing corro-
sion inhibitors for aluminum
engines
Mixing ratio
1:1 (antifreeze: water)
Quantity
Total amount
2.75 L
(2.42 lmp qt, 2.91 US qt)
Coolant reservoir capacity
0.25 L
(0.22 lmp qt, 0.26 US qt)
Handling notes for coolant
Coolant is potentially harmful and should
be handled with special care.
WARNINGWARNING
• If coolant splashes in your eyes, thor-
oughly wash them with water and
consult a doctor.
• If coolant splashes on your clothes,
quickly wash it away with water and
then with soap and water.
• If coolant is swallowed, induce vomit-
ing and get immediate medical atten-
tion.

3 - 35
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”.

3 - 36
CHK
ADJ
ADJUSTING THE REAR BRAKE
EB304001
CHASSIS
EB304010
ADJUSTING THE REAR BRAKE
1. Measure:
• brake pedal position
(distance a from the top of the brake
pedal to the bottom of the rider foot-
rest bracket)
Out of specification ® Adjust.
Brake pedal position (from the
top of the brake pedal to the
center of the rider footrest
bracket bolt)
31 ~ 36 mm (1.22 ~ 1.42 in)
a a
2. Adjust:
• brake pedal position
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. Loosen the locknut 1.
b. Turn the adjusting bolt 2 in direction
a or b until the specified brake pedal
position is obtained.
WARNINGWARNING
After adjusting the brake pedal position,
check that the end of the adjusting bolt
c is visible through the hole d.
c. Tighten the locknut 1 to specifica-
tion.
WARNINGWARNING
A soft or spongy feeling in the brake
pedal can indicate the presence of air in
the brake system. Before the vehicle is
operated, the air must be removed by
bleeding the brake system. Air in the
brake system will considerably reduce
braking performance and could result in
loss of control and possibly an accident.
Therefore, check and, if necessary,
bleed the brake system.Direction aBrake pedal is raised.
Direction bBrake pedal is lowered.
T R..
Locknut
16 Nm (1.6 m • kg, 11 ft • lb)

3 - 37
CHK
ADJADJUSTING THE REAR BRAKE/
CHECKING THE BRAKE FLUID LEVEL
ACHTUNG:CAUTION:
After adjusting the brake pedal position,
make sure that there is no brake drag.
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
3. Adjust:
• rear brake light switch
Refer to “ADJUSTING THE REAR
BRAKE LIGHT SWITCH”.
EB304020
CHECKING THE BRAKE FLUID LEVEL
1. Stand the motorcycle on a level surface.
NOTE:
• Place the motorcycle on a suitable
stand.
• Make sure that the motorcycle is
upright.
2. Check:
• brake fluid level
Below the minimum level mark a ®
Add the recommended brake fluid to
the proper level.
Front brake
õRear brake
WARNINGWARNING
• Use only the designated brake fluid.
Other brake fluids may cause the rub-
ber seals to deteriorate, causing leak-
age and poor brake performance.
• Refill with the same type of brake fluid
that is already in the system. Mixing
brake fluids may result in a harmful
chemical reaction, leading to poor
brake performance.
• When refilling, be careful that water
does not enter the brake fluid reser-
voir. Water will significantly lower the
boiling point of the brake fluid and
could cause vapor lock.
ACHTUNG:CAUTION:
Brake fluid may damage painted sur-
faces and plastic parts. Therefore,
always clean up any spilt brake fluid
immediately.
NOTE:
In order to ensure a correct reading of the
brake fluid level, make sure that the top of
the brake fluid reservoir is horizontal.
Recommended brake fluid
DOT 4

õ

3 - 38
CHK
ADJCHECKING THE BRAKE PADS/
ADJUSTING THE REAR BRAKE LIGHT SWITCH
EB304032
CHECKING THE BRAKE PADS
The following procedure applies to all of
the brake pads.
1. Operate the brake.
2. Check:
• front brake pad
• rear brake pad
Brake pad wear limit a
Wear limit reached ® Replace the
brake pads as a set.
Refer to “FRONT AND REAR BRAKES”
in chapter 7.
Front brake
õRear brake
Brake pad wear limit
0.5 mm (0.02 in)

õ
EB304050
ADJUSTING THE REAR BRAKE LIGHT
SWITCH
NOTE:
• The rear brake light switch is operated
by movement of the brake pedal.
• The rear brake light switch is properly
adjusted when the brake light comes
on just before the braking effect starts.
1. Check:
• rear brake light operation timing
Incorrect ® Adjust.
2. Adjust:
• rear brake light operation timing
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. Hold the main body 1 of the rear
brake light switch so that it does not
rotate and turn the adjusting nut 2 in
direction a or b until the rear brake
light comes on at the proper time.
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
Direction aBrake light comes on
sooner.
Direction bBrake light comes on
later.

3 - 39
CHK
ADJCHECKING THE BRAKE HOSES/
BLEEDING THE HYDRAULIC BRAKE SYSTEM
EB304062
CHECKING THE BRAKE HOSES
The following procedure applies to all of
the brake hoses and brake hose clamps.
1. Check:
• brake hose 1
Cracks/damage/wear ® Replace.
2. Check:
• brake hose clamp
Loose ® Tighten the clamp bolt.
3. Hold the motorcycle upright and apply
the brake several times.
4. Check:
• brake hose
Brake fluid leakage ® Replace the
damaged hose.
Refer to “FRONT AND REAR BRAKES”
in chapter 7.
EB304072
BLEEDING THE HYDRAULIC BRAKE
SYSTEM
WARNINGWARNING
Bleed the hydraulic brake system when-
ever:
• the brake system was disassembled,
• a brake hose was loosened, discon-
nected or replaced,
• the brake fluid level is very low,
• brake operation is faulty.
NOTE:
• Be careful not to spill any brake fluid or
allow the brake fluid reservoir to over-
flow.
• When bleeding the hydraulic brake
system, make sure that there is always
enough brake fluid before applying the
brake. Ignoring this precaution could
allow air to enter the hydraulic brake
system, considerably lengthening the
bleeding procedure.
• If bleeding is difficult, it may be neces-
sary to let the brake fluid settle for a
few hours. Repeat the bleeding proce-
dure when the tiny bubbles in the hose
have disappeared.

3 - 40
CHK
ADJ
BLEEDING THE HYDRAULIC BRAKE SYSTEM
1. Bleed:
• hydraulic brake system
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. Fill the brake fluid reservoir to the
proper level with the recommended
brake fluid.
b. Install the brake fluid reservoir dia-
phragm.
c. Connect a clear plastic hose 1 tightly
to the bleed screw 2.
Front brake
õRear brake
d. Place the other end of the hose into a
container.
e. Slowly apply the brake several times.
f. Fully squeeze the brake lever or fully
depress the brake pedal and hold it in
position.
g. Loosen the bleed screw.
NOTE:
Loosening the bleed screw will release
the pressure and cause the brake lever
to contact the throttle grip or the brake
pedal to fully extend.
h. Tighten the bleed screw and then
release the brake lever or brake
pedal.
i. Repeat steps (e) to (h) until all of the
air bubbles have disappeared from
the brake fluid in the plastic hose.
j. Tighten the bleed screw to specifica-
tion.
k. Fill the brake fluid reservoir to the
proper level with the recommended
brake fluid.
Refer to “CHECKING THE BRAKE
FLUID LEVEL”.
WARNINGWARNING
After bleeding the hydraulic brake sys-
tem, check the brake operation.
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
T R..
Bleed screw
6 Nm (0.6 m • kg, 4.3 ft • lb)

õ

3 - 41
CHK
ADJADJUSTING THE SHIFT PEDAL/
ADJUSTING THE DRIVE CHAIN SLACK
EB304081
ADJUSTING THE SHIFT PEDAL
NOTE:
The shift pedal position is determined
by the installed shift rod length a.
1. Measure:
• installed shift rod length a
Incorrect ® Adjust.
2. Adjust:
• installed shift rod length a
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. Loosen both locknuts 1.
b. Turn the shift rod 2 in direction b or
c to obtain the correct shift pedal
position.
c. Tighten both locknuts.
d. Make sure that the installed shift rod
length is within specification.
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
Installed shift rod length
294 mm (11.57 in)
Direction bInstalled shift rod length
decreases.
Direction cInstalled shift rod length
increases.
1
1
1
1
a a
b bc
c
EB304092
ADJUSTING THE DRIVE CHAIN SLACK
NOTE:
The drive chain slack must be checked at
the tightest point on the chain.
ACHTUNG:CAUTION:
A drive chain that is too tight will over-
load the engine and other vital parts,
and one that is too loose can skip and
damage the swingarm or cause an acci-
dent. Therefore, keep the drive chain
slack within the specified limits.
1. Stand the motorcycle on a level surface.
WARNINGWARNING
Securely support the motorcycle so that
there is no danger of it falling over.
NOTE:
Place the motorcycle on a suitable stand
so that the rear wheel is elevated.