engine coolant YAMAHA YZF-R7 1999 User Guide

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 - 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 - 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 - 29
–+ELECELECTRONIC FUEL INJECTION SYSTEM
1Main switch
5Battery
6Main fuse
CCamshaft sensor
DThrottle position sensor
EIntake air pressure sensor
FAtmospheric pressure sensor
GIntake air temperature sensor
HCoolant temperature sensor
IPickup coil
JECU
KCylinder #1-injector 1
LCylinder #2-injector 1
MCylinder #3-injector 1
NCylinder #4-injector 1
OCylinder #1-injector 2
PCylinder #2-injector 2
QCylinder #3-injector 2
RCylinder #4-injector 2
XFall detection switch
YSpeed sensor
yFuel pump
zMain relay
}Engine stop switch
ŒElectronic fuel injection system fuse
£ECU fuse
TROUBLESHOOTING
NOTE:
• Before troubleshooting, remove the following part(-s):
1) bottom cowling
2) front cowling
• Troubleshoot with the following special tool(-s).
The condition code is displayed by the tachometer.
Check the condition code list to
identify the faulty part. Refer to
“ELECTRICAL CONTROL SYS-
TEM”.
In diagnosis mode, select the
appropriate diagnosis code to
check the operation of the faulty
part.Check the
wiring.Replace.
Co, diagnosis switch box
90890-03171
Test coupler adapter
90890-03149
Out of specifi-
cationNo good

8 - 32
–+ELECELECTRICAL CONTROL SYSTEM
Condition code list
NOTE:
* This condition code is also displayed in the following cases:
- when the starter switch is held down for more than 4 seconds, causing the warning
light to flash
- when the ignition circuit cut-off system stops the engine or prevents it from starting
** This condition code is also displayed when the engine is operated at 5,000 r/min for at
least 30 seconds with the rear wheel at standstill.
*** This condition code is also displayed when the engine stop switch is turned to “ ”
while riding with the transmission in gear. Condition
codeCircuit Defect(s) System response
11 Camshaft sensor • No incoming sig-
nalThe ECU pairs the ignition of cyl-
inders #1 and #4 and cylinders #2
and #3. The motorcycle can be
ridden.
12* Pickup coil • No incoming sig-
nalThe motorcycle cannot be ridden.
13 Intake air pressure
sensor• Disconnected
• Short-circuitThe ECU stays set to an intake air
pressure of 760 mm Hg (29.9 in Hg).
The motorcycle can be ridden.
14 Intake air pressure
sensor hose and
negative pressure
hose• Improper connec-
tion
• Bending
15 Throttle position
sensor• Disconnected
• Short-circuitThe ECU stays set to a wide throt-
tle opening.
The motorcycle can be ridden.
16 Throttle position
sensor• Locked
21 Coolant tempera-
ture sensor• Disconnected
• Short-circuitThe ECU stays set to a coolant
temperature of 80˚C (176˚F).
The motorcycle can be ridden.
22 Intake air tempera-
ture sensor• Disconnected
• Short-circuitThe ECU stays set to an intake air
temperature of 40˚C (104˚F).
The motorcycle can be ridden.
23 Atmospheric pres-
sure sensor• Disconnected
• Short-circuitThe ECU stays set to an atmo-
spheric pressure of 760 mm Hg
(29.9 in Hg).
The motorcycle can be ridden.
41 Fall detection
switch• Disconnected The main relay stays switched off.
The motorcycle cannot be ridden.
42** Speed sensor • Incorrect signal The ECU stays set to 6th gear.
The motorcycle can be ridden.
43*** Monitored voltage • Incorrect The ECU stays set to a monitored
voltage of 12 V.
The motorcycle can be ridden.
44 ROM operation • CO emission
adjustment errorThe CO emission adjustment is
set to 0.

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