coolant YAMAHA YZF-R7 1999 User Guide

2 - 31
SPEC
KPickup coil lead
LStator coil lead
MSpeed sensor lead
NSidestand switch lead
OOil level switch lead
PCoolant reservoir breather hose
QWire harness
RWire harness lead (to fall detection
switch coupler)
SWire harness lead (to fuse box)
TStarter motor leadUNeutral switch lead
VGround lead
WCoolant temperature sensor coupler
XThrottle cable
Route the wire harness in front of the ignition coils.
õBe sure that there is no slack in the tail/brake light lead
and rear turn signal leads below the rear fender panel.
‚Align the portions of the wire harness, ground lead and
starter motor lead marked with white tape with the lead
holder.
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

3 - 31
CHK
ADJ
CHECKING THE COOLANT LEVEL
EB303220
CHECKING THE COOLANT 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. Remove:
• bottom cowling
• front cowling
Refer to “COWLINGS”.
3. Check:
• coolant level
The coolant level should be between
the minimum level mark a and maxi-
mum level mark b.
Below the minimum level mark ® Add
the recommended coolant to the
proper level.
ACHTUNG:CAUTION:
• Adding water instead of coolant lowers
the antifreeze content of the coolant. If
water is used instead of coolant, check
and if necessary, correct the antifreeze
concentration of the coolant.
• Use only distilled water. However,
soft water may be used if distilled
water is not available.
4. Start the engine, warm it up for several
minutes, and then turn it off.
5. Check:
• coolant level
NOTE:
Before checking the coolant level, wait a
few minutes until the coolant has set-
tled.
aa b
b

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”.

ENG

4 - 3
ENGINE
T R..20 Nm (2.0 m • kg, 14 ft • Ib)
T R..20 Nm (2.0 m • kg, 14 ft • Ib)
T R..24 Nm (2.4 m • kg, 17 ft • Ib)
T R..10 Nm (1.0 m • kg, 7.2 ft • Ib)
T R..20 Nm (2.0 m • kg, 14 ft • Ib)
1
2
25654
3(8)
7New
T R..38 Nm (3.8 m • kg, 27 ft • Ib)
T R..28 Nm (2.8 m • kg, 20 ft • Ib)

Order Job/Part Q’ty Remarks
Removing the exhaust assembly
Remove the parts in the order listed.
Rear cowling Refer to “COWLINGS” in chapter 3.
Coolant Drain.
Refer to “CHANGING THE COOLANT”
in chapter 3.
Radiator assembly Refer to “RADIATOR AND THERMO-
STAT” in chapter 5.
1 Muffler 1
2 Spring 4
3 Exhaust pipe assembly 1
4 Exhaust pipe joint 1 1
5 Exhaust pipe joint 2 2
6 Exhaust pipe joint 4 1
7 Exhaust pipe joint gasket 4
For installation, reverse the removal
procedure.

ENG
4 - 50
OIL PAN AND OIL PUMP
EB411000
OIL PAN AND OIL PUMP
Order Job/Part Q’ty Remarks
Removing the oil pan and oil pumpRemove the parts in the order listed.
Engine oil Drain.
Refer to “CHANGING THE ENGINE
OIL” in chapter 3.
Coolant Drain.
Refer to “CHANGING THE COOLANT”
in chapter 3.
Radiator assembly and water pump
outlet pipeRefer to “RADIATOR AND THERMO-
STAT” and “OIL COOLER” in chapter 5.
Exhaust pipe assembly Refer to “ENGINE”.
1 Oil level switch connector 1 Disconnect.
2 Oil level switch 1
3 Oil level switch lead holder 1
4 Oil pan 1
5 Oil pan gasket 1
6 Dowel pin 2

5 - 1
COOL

RADIATOR AND THERMOSTAT
EB500000
COOLING SYSTEM
RADIATOR AND THERMOSTAT
Order Job/Part Q’ty Remarks
Removing the radiator
Remove the parts in the order listed.
Bottom cowling and front cowling Refer to “COWLINGS” in chapter 3.
Coolant Drain.
Refer to “CHANGING THE COOLANT”
in chapter 3.
1 Coolant reservoir breather hose 1
2 Coolant reservoir hose 1
3 Coolant reservoir 1
4 Thermo switch 1
5 Thermostat assembly breather hose 1 Disconnect.
6 Water pump inlet pipe 1
7 Water pump breather hose 1
8 Radiator outlet pipe breather hose 1
9 Water pump inlet hose 1
10 Radiator outlet pipe 1
5

5 - 3
COOL

EB502000
RADIATOR AND THERMOSTAT
Order Job/Part Q’ty Remarks
Removing the thermostat assembly
Remove the parts in the order listed.
Rider seat and fuel tank Refer to “SEATS” and “FUEL TANK” in
chapter 3.
Air filter case and rubber cover Refer to “AIR FILTER CASE AND IGNI-
TION COIL PLATE” in chapter 3.
Carburetor assembly Refer to “CARBURETORS” in chapter 6.
Coolant Drain.
Refer to “CHANGING THE COOLANT”
in chapter 3.
Fuel tank and air filter case cover Refer to “FUEL TANK AND AIR FIL-
TER” in chapter 3.
Air filter case Refer to “ELECTRONIC FUEL INJEC-
TION” in chapter 6.
1 Thermostat assembly 1
2 Thermostat assembly inlet hose 1
RADIATOR AND THERMOSTAT