engine YAMAHA YZF-R7 1999 Owners Manual

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–+ELECELECTRICAL CONTROL SYSTEM
DIAGNOSIS MODE
There are two operation methods for this mode: one is performed using the CO, diagnosis
switch box, the other is performed using the test coupler adapter. With the CO, diagnosis
switch box method, the switches on the CO, diagnosis switch box are used. With the test cou-
pler adapter method, the start switch and the engine stop switch are used. The procedures for
selecting and using each method is explained below.
NOTE:
The engine cannot be started, the vehicle cannot be ridden, and no other mode can be
selected while either of the diagnosis mode operation methods is being performed.
CO, diagnosis switch box method
• Remove the bottom cowling and the front
cowling.
Refer to “COWLINGS” in chapter 3.
• Remove the protection cap 1 from the EFI
test coupler 2.
• Connect the CO, diagnosis switch box 3
to the EFI test coupler 2.
• Turn the main switch to “ON”.
• Turn the engine stop switch to “ ”.
• Within 4 seconds, press the following
switches on the CO, diagnosis switch box
in the order indicated to enter the diagno-
sis mode.
4MODE switch = 1
5UP switch = 2
6DOWN switch = 3
1 ® 2 ® 1 ® 3 ® 1 ® 2 ® 1 ® 3 ® 1 ® 2 ®
1 ® 3
The warning light flashes when the unit has
entered the diagnosis mode.
NOTE:
Turn the main switch to “OFF” to cancel the
diagnosis mode.
CO, diagnosis switch box
90890-03171

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–+ELECELECTRICAL CONTROL SYSTEM
Test coupler adapter method
• Remove the bottom cowling and the front
cowling.
Refer to “COWLINGS” in chapter 3.
• Remove the protection cap 1 from the EFI
test coupler 2.
• Connect the test coupler adapter 3 to the
EFI test coupler 2.
• Disconnect the fuel pump coupler from
the wire harness.
• Turn the main switch to “ON”.
• Turn the engine stop switch to “ ”.
• Press the start switch ten times within 4
seconds to enter the diagnosis mode.
The warning light flashes when the unit
has entered the diagnosis mode.
NOTE:
Turn the main switch to “OFF” to cancel the
diagnosis mode.
Operation after entering the diagnosis
mode
• Select a diagnosis code by pressing the
start switch. Refer to the diagnosis code
list.
First, press the start switch once to select
diagnosis code 01. Afterwards, each press
of the start switch increases the diagnosis
code number by one. If diagnosis code 31
is selected, pressing the start switch once
selects diagnosis code 00.
• Turn the engine stop switch to “ ” to
start the test for the selected diagnosis
code.
NOTE:
To select another diagnosis code, turn the
engine stop switch to “ ”, and then press
the start switch.
Example:
First, select diagnosis code 29 as follows.
• Turn the engine stop switch to “ ”.
• Press the start switch 29 times.
• Turn the engine stop switch to “ ”.
Next, select diagnosis code 10 as follows.
• Turn the engine stop switch to “ ”.
• Press the start switch 13 times.
• Turn the engine stop switch to “ ”.
Test coupler adapter
90890-03149

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–+ELECELECTRICAL CONTROL SYSTEM
12 Main relay CO, diagnosis switch box method
Within one second after the
MODE switch is released, the
main relay is switched on once
every second for the next five
seconds. During this time, the
warning light lights up as long as
the relay is switched on.
Test coupler adapter method
Within one second after the
engine stop switch is turned to
“ ”, the main relay is switched
off, then on again. The warning
light lights up while the relay is
switched off.
13 Ignition coil for
cylinder #1CO, diagnosis switch box method
Within one second after the
MODE switch is released, the
ignition coil for the selected cylin-
der is operated once every sec-
ond for the next five seconds.
During this time, the warning
light lights up for 0.5 second
once every second.
Test coupler adapter method
Within one second after the
engine stop switch is turned to
“ ”, the ignition coil for the
selected cylinder is operated
once every second for the next
five seconds. During this time,
the warning light lights up for 0.5
second once every second. 14 Ignition coil for
cylinder #2
15 Ignition coil for
cylinder #3
16 Ignition coil for
cylinder #4 Diagnosis
codeInspected item System responseTachometer display
(0 ~ 10,000 r/min)

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–+ELECELECTRICAL CONTROL SYSTEM
17 Injector 1 for cyl-
inder #1CO, diagnosis switch box method
Before selecting a code, discon-
nect the fuel pump coupler from
the wire harness.
Within one second after the
MODE switch is released, the
main relay is turned on, and the
selected injector is operated once
every second for the next five
seconds. During this time, the
warning light lights up for 0.5
second once every second.
Test coupler adapter method
Within one second after the
engine stop switch is turned to
“ ”, the selected injector is
operated for once every second
for the next five seconds. During
this time, the warning light lights
up for 0.5 second once every sec-
ond. 18 Injector 1 for cyl-
inder #2
19 Injector 1 for cyl-
inder #3
20 Injector 1 for cyl-
inder #4
21 Injector 2 for cyl-
inder #1
22 Injector 2 for cyl-
inder #2
23 Injector 2 for cyl-
inder #3
24 Injector 2 for cyl-
inder #4
25 ~ 28 — — —
29 Condition code
record of mal-
functionsThe condition code of any fixed mal-
function is recorded in the ROM and
displayed by the tachometer. Refer
to the condition code list in “USER
MODE” for details on the condition
codes.Condition codes 11
– 44
30 ROM (Clearing
the condition
code record)Selecting this diagnosis code clears
the condition code record of mal-
functions stored in the ROM.
If an error has occurred in a sensor
signal, it was recorded in the ROM
and the tachometer displays 10,000
r/min. If no error has occurred, the
tachometer displays 0 r/min.
CO, diagnosis switch box method
Press the UP switch eight times
within four seconds to clear the con-
dition code record from the ROM.
Test coupler adapter method
Remove the rear cowling.
Disconnect the relay unit coupler
from the relay unit.
Press the start switch ten times
within four seconds to clear the con-
dition code record from the ROM.0 r/min (no error) or
10,000 r/min (errors)
When the error
record is cleared, 0
r/min is displayed.
31 ROM program
versionThe version number of the ROM pro-
gram is displayed in the tachometer. Diagnosis
codeInspected item System responseTachometer display
(0 ~ 10,000 r/min)

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–+ELECELECTRICAL CONTROL SYSTEM
CO EMISSION ADJUSTMENT MODE
With the CO emission adjustment mode,
the amount of fuel injected by the injector
can be adjusted.
NOTE:
Prior to adjusting the CO emission, the
throttle bodies must be properly synchro-
nized.
• Remove the bottom cowling and front
cowling.
Refer to “COWLINGS” in chapter 3.
• Remove the CO check bolts from the
exhaust pipe assembly.
• Install the exhaust attachment 1 and CO
tester 2 to the exhaust pipe assembly.
• Attach the engine tachometer to the igni-
tion coil for cylinder #1.
Refer to “SYNCHRONIZING THE THROT-
TLE BODIES” in chapter 3.
• Remove the protection cap 3 from the EFI
test coupler 4.
• Connect the CO, diagnosis switch box 5
to the EFI test coupler 4.
• Start the engine and let it warm up for
several minutes.
Exhaust attachment
90890-03134
Engine tachometer
90890-06760
CO, diagnosis switch box
90890-03171
Engine idling speed
1,000 ~ 1,200 r/min
2

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–+ELECELECTRICAL CONTROL SYSTEM
• Within 4 seconds, press the following
switches on the CO, diagnosis switch box
in the order indicated to enter the CO
emission adjustment mode.
6MODE switch = 1
7UP switch = 2
8DOWN switch = 3
1 ® 2 ® 3 ® 1 ® 2 ® 3 ® 1 ® 2 ® 3 ® 1 ®
2 ® 3
The warning light flashes for 1.4 seconds
when the unit has entered the CO emission
adjustment mode. During this time, the
tachometer displays the engine idling
speed.
NOTE:
Turn the main switch to “OFF” to cancel the
CO emission adjustment mode.
• According to the following table, select
the cylinder to be adjusted by holding
down the MODE switch while pressing
either the UP switch or the DOWN switch.
• Release the MODE switch to start the CO
emission adjustment for the selected cyl-
inder. The warning light flashes once
every 0.5 second and the tachometer dis-
plays the engine speed.
• While watching the CO tester, press the
UP switch or DOWN switch to adjust the
CO emission.
NOTE:
• If the UP switch is pressed when the CO
emission has reached its maximum or if
the DOWN switch is pressed when the CO
emission has reached its minimum, the
warning light flashes once every 0.16 sec-
ond. Tachometer display Selected cylinder
1,000 r/min Cylinder #1
2,000 r/min Cylinder #2
3,000 r/min Cylinder #3
4,000 r/min Cylinder #4
Press the UP switch Increase CO emis-
sion
Press the DOWN
switchDecrease CO emis-
sion

YZF-R7 WIRING DIAGRAM
1
Main switch

2
Rectifier/regulator

3
Generator

4
Backup fuse (odometer)

5
Battery

6
Main fuse

7
Starter relay

8
Starter motor

9
Diode

0
Relay unit

A
Diode

B
Sidestand switch

C
Camshaft sensor

D
Throttle position sensor

E
Intake air pressure sensor

F
Atmospheric pressure sensor

G
Intake air temperature sensor

H
Coolant temperature sensor

I
Pickup coil

J
ECU

K
Cylinder #1 - injector 1

L
Cylinder #2 - injector 1

M
Cylinder #3 - injector 1

N
Cylinder #4 - injector 1

O
Cylinder #1 - injector 2

P
Cylinder #2 - injector 2

Q
Cylinder #3 - injector 2

R
Cylinder #4 - injector 2

S
Cylinder #1 - ignition coil

T
Cylinder #2 - ignition coil

U
Cylinder #3 - ignition coil

V
Cylinder #4 - ignition coil

W
CDI unit

X
Fall detection switch

Y
Speed sensor

Z
Neutral switch

[
Meter assembly

\
Fuel level indicator light

]
Warning light (oil level indicator)

^
Neutral indicator light

a
Tachometer

b
Combination meter

c
Warning light (coolant temperature indicator)
d
High beam indicator light
e
Turn signal indicator light
f
Meter light
gWarning light (engine trouble indicator)
hOil level switch
i
Horn
jHeadlight
kRear turn signal light (right)
lRear turn signal light (left)
mFront turn signal light (right)
nFront turn signal light (left)
oTail/brake light
pRear brake light switch
q
Left handlebar switch
rClutch switch
sLights switch
t
Pass switch
uDimmer switch
vTurn signal switch
wHorn switch
xTurn signal relay
yFuel pump
zMain relay
{
Right handlebar switch|Front brake light switch
}Engine stop switch
~Start switch
Œ
Electronic fuel injection system fuseCYCLELOCK Signaling system fuse
¢Headlight fuse£
ECU fuse¤Radiator fan motor fuse
¥Thermo switch
¦Radiator fan motor
COLOR CODE
B ............ black
Br ........... brown
Ch .......... chocolate
Dg .......... dark green
G ............ green
Gy .......... gray
L ............ blue
Lg .......... light green
O ............ orange
P ............ pink
R ............ red
Sb .......... sky blue
W ........... white
Y ............ yellow
B/L ......... black/blue
B/R ......... black/red
B/W ....... black/white
B/Y ......... black/yellow
Br/G ....... brown/green
Br/L ........ brown/blue
Br/R ....... brown/red
Br/W ...... brown/white
G/B ........ green/black
G/R ........ green/red
G/W ....... green/white
G/Y ........ green/yellow
Gy/B ...... gray/black
Gy/G ...... gray/green
Gy/R ...... gray/red
L/B ......... blue/black
L/G ......... blue/green
L/R ......... blue/red
L/W ........ blue/white
L/Y ......... blue/yellow
Lg/R ....... light green/red
Lg/Y ....... light green/yellow
O/B ........ orange/black
O/G ........ orange/green
P/B ......... pink/black
P/L ......... pink/blue
P/W ........ pink/white
R/B ......... red/black
R/G ........ red/green
R/L ......... red/blue
R/W ....... red/white
R/Y ......... red/yellow
W/B ....... white/black
W/G ....... white/green
W/L ........ white/blue
W/Y ....... white/yellow
Y/B ......... yellow/black
Y/G ........ yellow/green
Y/L ......... yellow/blue
Y/R ......... yellow/rod