cooling YAMAHA YZF-R7 1999 User Guide

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.

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 - 6
COOL

RADIATOR AND THERMOSTAT
EB500010
CHECKING THE RADIATOR
1. Check:
• radiator fins
Obstruction
®
Clean.
Apply compressed air to the rear of the
radiator.
Damage
®
Repair or replace.
NOTE:

Straighten any flattened fins with a thin,
flat-head screwdriver.
2. Check:
• radiator hoses
Cracks/damage
®
Replace.
3. Measure:
• radiator cap opening pressure
Below the specified pressure
®
Replace the radiator cap.
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. Install the radiator cap tester
1
and
adapter
2
onto the radiator cap
3
.
b. Apply the specified pressure for ten
seconds and make sure that there is
no drop in pressure.
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
Radiator cap opening pressure
95 ~ 125 kPa
(0.95 ~ 1.25 kg/cm
2

,
3.51 ~ 7.78 psi)
Radiator cap tester
90890-01325
Adapter
90890-01352
4. Check:
• radiator fan
Damage
®
Replace.
Malfunction
®
Check and repair.
Refer to “COOLING SYSTEM” in chap-
ter 8.

5 - 7
COOL

RADIATOR AND THERMOSTAT
EB502020
CHECKING THE THERMOSTAT
1. Check:
• thermostat
1

Does not open at 71 ~ 85 ˚C (159.8 ~
185 ˚F)
®
Replace.
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. Suspend the thermostat in a con-
tainer filled with water.
b. Slowly heat the water.
c. Place a thermometer in the water.
d. While stirring the water, observe the
thermostat and thermometer’s indi-
cated temperature.
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
1
Thermostat
2
Thermometer
3
Water
4
Container

Fully closed
õ
Fully open
NOTE:

If the accuracy of the thermostat is in
doubt, replace it. A faulty thermostat
could cause serious overheating or
overcooling.
2. Check:
• thermostat housing cover
• thermostat housing
Cracks/damage
®
Replace.
EB502030
ASSEMBLING THE THERMOSTAT
ASSEMBLY
1. Install:
• thermostat housing
1

• thermostat
2

• thermostat housing cover
NOTE:

Install the thermostat with its breather
hole
a
facing up.
2
1
1
2
a a

5 - 8
COOL

RADIATOR AND THERMOSTAT
INSTALLING THE THERMOSTAT
ASSEMBLY AND RADIATOR
1. Fill:
• cooling system
(with the specified amount of the rec-
ommended coolant)
Refer to “CHANGING THE COOLANT”
in chapter 3.
2. Check:
• cooling system
Leaks
®
Repair or replace any faulty
part.
3. Measure:
• radiator cap opening pressure
Below the specified pressure
®
Replace the radiator cap.
Refer to “CHECKING THE RADIATOR”.

5 - 11
COOLOIL COOLER
3. Fill:
• cooling system
(with the specified amount of the rec-
ommended coolant)
Refer to “CHANGING THE COOLANT”
in chapter 3.
• crankcase
(with the specified amount of the rec-
ommended engine oil)
Refer to “CHANGING THE ENGINE
OIL” in chapter 3.
4. Check:
• cooling system
Leaks ® Repair or replace any faulty
part.
5. Measure:
• radiator cap opening pressure
Below the specified pressure ®
Replace the radiator cap.
Refer to “CHECKING THE RADIATOR”.

8 - 24
–+ELECCOOLING SYSTEM
EB807000
COOLING SYSTEM
CIRCUIT DIAGRAM
B
(BLACK) (DARK GRAY)
(BLACK)B
L
B
L
K
WWW
86
7RR
Br
BBRR
L/W BrL/W
RR
R
B
B
BBB
B
R
WWW(BLACK)
L/W
B
R/B
R/L
G/B
R/L
L/W
B (BLUE)
Gy
Gy/B
B
B(BLUE)
Gy
B
Br
G
L/R
B
Br
G L/R
B
Br/W
Br
B
B
B
B
L/WBr
R/W
G/Y R/W
B/WB/L(GRAY)
(BROWN)
h
Br
YB
BBr
Y (BROWN) (BROWN)
R/YLBr/WP
B(BLUE) (BLUE)(BLACK) (BLACK)
Br
BBR/WR/B
Y
P
ON OFF
R
RL/R
LBr/L
B
R/L
G/W(BLACK)
R/L R/BR/G L/R(GREEN)
(BLACK) (BLACK)(BLACK)(BLACK)
O Gy
B
Br/G
B Br
L/G W/G
Y/G
BYL
B
B
G
Ch Dg
BL/W
L/R
R/BB/Y
L/YSb
R/L R/B
Br/WB1G/W B/L
L/Y
W
B/L
W/B L/YB/L
W/YL/Y
L/Y
Br L
R
Br/LR
Br/L
L/W
L/Y
Br
L/W
L/Y L/B
L L/R
B L/Y
L/R LB B BB
W
WW
W
WW
B
BB
B
B B1
B
BB
B
B
B/YL/Y
B/YL/Y
R/Y
L P
B Br/WDg
ChB/YYG
L/Y
Ch
B/YDg
G
L/YY
B
R
G
B/L
YLWBYPBL
GBB/W
(BLACK)YB
BCh
(BLACK)BDg
B
(GRAY)(BLACK)
(BLACK)
(BLACK) (GRAY)
(GRAY)
(GRAY)
(GRAY) (GRAY)B/W B/L
B/L B/L
W/LP/B Y/L
R
B
PASS
(BLACK)
(BLACK)ChB
(BLACK)DgB
N
B(BLACK)B
(BLACK) (BLACK)
O/G B(BLACK) (BLACK)
L
R/L G/B
M
R/L L/B
N
R/LR/L O/B
OY
Y/R C YG/R C GBr/R C BrGy/R C Gy
R R/LRRRRY
P
RG G(BROWN)
Q
RBr Br
Gy(DARK GRAY)R(GRAY)
R
R/YLg/Y
R/Y Lg/Y R/WB/L
R/Y
R
Y/L
B
L/R
YL/R
Gy/B
Gy
G/WB1
W/Y
W1
L/R B/L
YLW/B
Y/L W/L
P/W P/LR/Y
Br/W R/W
Lg/YL/W B/W
R/L
R/B L/WW G
Lg
L/R L/BSb
B/Y B B/R L/Y
RBR
R/G
4
BL/Y
BB
Br/L
BrBrL
B
B
BR/GB1
B
Y
B
R/WR/B
R/GR/BL/RR/L
Br
G/WR/L
L/YW/BB/L
GyGy/B
R/L
L/R
L/W
B/LL
B
Br/W
Br
Y
LPWP
B2
B2
R PB
(BLACK)
B3
B3W2
Y/G L/GBr/G Br/R
Gy/R
BrBrO/B
G/Y L/B G/B G/R
Y/R
W/G Y/B R/B
O/B
R/L
L/B
GyO
O Lg/R
B
B
B
BB Gy
Gy/G Gy/G Gy/G
O/G O/GO/G
Gy GyGy/G
Br/G
W/G
Y/G
L/G
Br
WW/YB/L
L/Y
Lg/RG/Y W/YL/R
Y/B
L/YBSb
Sb
R/GG/WWYChL
W
BrP
P G Y Ch Dg B
Dg
B
BBBB
B
Dg
ChBr
LR/Y
L/Y B/Y
Br/LBr/LBr/L
BrR/YR/W
Gy/BB3
R/B
G/B
L/B
O/B
Gy/R
Lg/RY/R
G/R
Br/R
R/W
R/Y
Lg/Y
W1
W2
(BLACK)
(BLACK)
(BLACK)
(BLACK) (GRAY)
B
L
B
B/L
Br/W
B/LG/W
S
T
U
V W J
Z
R/G
B L/Y
W/YG/Y W Y/B
Br
G/WLg/R Lg Y
ChDg
L
gf f e dc b a` ] \[ FE DC
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G
H
X
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op
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1
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(BLACK)
Y
L/W
Y/B
G/Y
Y/L
W/L
P/BR
B3 W/B
B/L
L
Y
P/W
P/L
Br
G/W
B/W
W/Y
Br
B2
|
~
z } {
L/Y
A
A
A
A
AA
AAAA
A C
A
A
A
A A
A
P/LP/W
BB/L BB/L
DL DL
C
W/LP/B
WIRE HARNESS SUB LEAD
B/L B/L
BB
R/L R/L L
R/L R/L L
LRR
LR
R(GRAY)
(GRAY)
WIRE HARNESS SUB LEADY/R
Br/RP/W
G/R Gy/R P/L
WYBr
PG
Gy(BLACK)
(BLACK)
WIRE HARNESS SUB LEAD HEADLIGHT AND METER SUB-WIRE HARNESS
(BLACK)
(BLACK)
WIRE HARNESS
Y W/Y G/WG/W
R/G L G/Y Dg
Br
GY
G L/YW/Y
L/Y BBr
B W Y/B Lg Lg/RCh L/R
L/R
G/Y
R/GDg
L
Lg/R
Lg
W
Y/B ChA
BC
D
D R/L D R/L D R/L D
R
B1
Br/G
W/G
Y/G
L/G
Br
BB
B2
Gy
1Main switch
5Battery
6Main fuse
¤Radiator fan motor fuse
¥Thermo switch
¦Radiator fan motor

8 - 25
–+ELECCOOLING SYSTEM
TROUBLESHOOTING
C0NTINUITYOK
C0NTINUITYOK
C0NTINUITYOK
C0NTINUITYOK
C0NTINUITYOK
NOTE:
• Before troubleshooting, remove the following part(-s):
1) bottom cowling
2) front cowling
3) rear cowling
• Troubleshoot with the following special tool(-s).
• The radiator fan motor fails to turn.
• The coolant temperature meter needle fails to move when the engine is warm.
Check the main and radiator fan
motor fuses for continuity.Replace.
Check the condition of the bat-
tery.Recharge or replace.
Check the main switch. Replace.
Check the radiator fan motor. Replace.
Check the thermo switch. Replace.
Check the entire cooling system’s
wiring.Repair or replace.
Pocket tester
90890-03112
No good
No good
No good
No good
No good
No good

8 - 26
–+ELECCOOLING SYSTEM
CHECKING THE THERMO SWITCH
• Remove the thermo switch from the radia-
tor.
• Connect the pocket tester (W ´ 1) to the
thermo switch 1 as shown.
• Immerse the thermo switch in a container
filled with coolant 2.
NOTE:
Make sure that the thermo switch terminals
do not get wet.
• Place a thermometer 3 in the coolant.
• Slowly heat the coolant, then let it cool to
the specified temperature as indicted in
the table.
• Check the thermo switch for continuity a
the temperatures indicated in the table.
WARNINGWARNING
• Handle the thermo switch with special
care.
• Never subject the thermo switch to
strong shocks. If the thermo switch is
dropped, replace it.
The thermo switch circuit is open and the
radiator fan is off.
õThe thermo switch circuit is closed and the
radiator fan is on.
• Does the thermo switch operate properly
as described above?
Yes ® OK.
No ® Replace.
Test stepCoolant temperature
Continuity
Thermo switch
10 ~ 100 ± 3˚C
(0 ~ 212 ± 37.4˚F)NO
2
More than 105 ± 3˚C
(221 ± 37.4˚C)YES
3*
105 to 100 ˚C
(221 to 212 ˚F)YES
4*
Less than 100 ˚C (212 ˚F)NO
Test steps 1 & 2: Heating phase
Test steps 3* & 4*: Cooling phase
T R..
Thermo switch
23 Nm (2.3 m • kg, 17 ft • lb)
Three bond sealock
® 10