ignition YAMAHA YZF-R7 1999 User Guide

3 - 14
CHK
ADJADJUSTING THE VALVE CLEARANCE/
SYNCHRONIZING THE THROTTLE BODIES
g. Measure the valve clearance again.
h. If the valve clearance is still out of
specification, repeat all of the valve
clearance adjustment steps until the
specified clearance is obtained.
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
8. Install:
• all removed parts
NOTE:
For installation, reverse the removal
procedure. Note the following points.
SYNCHRONIZING THE THROTTLE BODIES
NOTE:
Prior to synchronizing the throttle
bodies, the valve clearance and the
engine idling speed should be properly
adjusted and the ignition timing should
be checked.
1. Stand the motorcycle on a level surface.
NOTE:
Place the motorcycle on a suitable
stand.
2. Remove:
• fuel tank
Refer to “FUEL TANK AND AIR FIL-
TER”.
• bottom cowling
• front cowling
Refer to “COWLINGS”.
3. Remove:
• bolts 1
• copper washers
11

3 - 15
CHK
ADJ
SYNCHRONIZING THE THROTTLE BODIES
4. Install:
• vacuum gauge attachments
(into the bolt holes)
• vacuum gauge
(onto the vacuum gauge attachments)
• engine tachometer
(onto the ignition coil of cylinder #1)
NOTE:
Disconnect the ignition coil coupler and
remove the ignition coil 1 of cylinder
#1, remove the rubber cover 2, and
wrap the engine tachometer lead sev-
eral times around section a of the igni-
tion coil. Then, install the ignition coil
and connect the ignition coil coupler.
5. Install:
• fuel tank
Refer to “FUEL TANK AND AIR FIL-
TER”.
6. Start the engine and let it warm up for
several minutes.
Vacuum gauge
90890-03094
Vacuum gauge attachment
90890-03060
Engine tachometer
90890-06760
1 1
2
2
a
a
7. Measure:
• engine idling speed
Out of specification ® Adjust.
Refer to “ADJUSTING THE ENGINE
IDLING SPEED”.
Engine idling speed
1,000 ~ 1,200 r/min
8. Adjust:
• throttle body synchronization
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. Turn the air screws 1 to adjust the
vacuum pressure of all throttle bodies
to specification.
NOTE:
Do not turn the synchronizing screws.1 11 1

3 - 17
CHK
ADJADJUSTING THE ENGINE IDLING SPEED/
ADJUSTING THE THROTTLE CABLE FREE PLAY
3. Install:
• engine tachometer
(onto the ignition coil of cylinder #1)
NOTE:
Refer to “SYNCHRONIZING THE THROT-
TLE BODIES” for the engine tachometer
installation.
4. Measure:
• engine idling speed
Out of specification ® Adjust.
Engine tachometer
90890-06760
Engine idling speed
1,000 ~ 1,200 r/min
5. Adjust:
• engine idling speed
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. Turn the throttle stop screw 1 in
direction a or b until the specified
engine idling speed is obtained.
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
6. Adjust:
• throttle cable free play
Refer to “ADJUSTING THE THROTTLE
CABLE FREE PLAY”. Direction aEngine idling speed is
increased.
Direction bEngine idling speed is
decreased.
Throttle cable free play
(at the flange of the throttle
grip)
3 ~ 5 mm (0.12 ~ 0.20 in)
a a b b
1
1
EB303031
ADJUSTING THE THROTTLE CABLE FREE
PLAY
NOTE:
Prior to adjusting the throttle cable free
play, the engine idling speed and throt-
tle body synchronization should be
adjusted properly.

3 - 19
CHK
ADJADJUSTING THE THROTTLE CABLE FREE PLAY/
CHECKING THE SPARK PLUGS
Handlebar side
a. Loosen the locknut 4.
b. Turn the adjusting nut 5 in direction
c or d until the specified throttle
cable free play is obtained.
c. Tighten the locknut.
WARNINGWARNING
After adjusting the throttle cable free
play, start the engine and turn the han-
dlebars to the right and to the left to
ensure that this does not cause the
engine idling speed to change.
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 cThrottle cable free play
is increased.
Direction dThrottle cable free play
is decreased.
C C
d d
7
7
5
57
7
4
4
EB303040
CHECKING THE SPARK PLUGS
The following procedure applies to all of
the spark plugs.
1. Remove:
• fuel tank
• air filter case cover
Refer to “FUEL TANK AND AIR FIL-
TER”.
• air filter case
Refer to “ELECTRONIC FUEL INJEC-
TION” in chapter 6.
2. Disconnect:
• ignition coil couplers
3. Remove:
• ignition coils
• spark plug
ACHTUNG:CAUTION:
Before removing the spark plugs, blow
away any dirt accumulated in the spark
plug wells with compressed air to pre-
vent it from falling into the cylinders.
4. Check:
• spark plug type
Incorrect ® Change.
Spark plugs
Model (manufacturer)
R0256R-10 (NGK)

3 - 21
CHK
ADJ
MEASURING THE COMPRESSION PRESSURE
3. Remove:
• fuel tank
• air filter case cover
Refer to “FUEL TANK AND AIR FIL-
TER”.
• air filter case
• throttle body assembly
Refer to “ELECTRONIC FUEL INJEC-
TION” in chapter 6.
• ignition coil
4. Remove:
• spark plug
ACHTUNG:CAUTION:
Before removing the spark plugs, use
compressed air to blow away any dirt
accumulated in the spark plug wells to
prevent it from falling into the cylinders.
5. Install:
• compression gauge 1
• adapter 2
Compression gauge
90890-03081
Adapter
90890-04136
1
1

2

2

6. Measure:
• compression pressure
Out of specification ® Refer to steps
(c) and (d).
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. Set the main switch to “ON”.
b. With the throttle wide open, crank the
engine until the reading on the com-
pression gauge stabilizes.
Compression pressure (at sea
level)
Minimum
1,500 kPa
(15.0 kg/cm
2, 213 psi)
Standard
1,600 kPa
(16.0 kg/cm
2, 228 psi)
Maximum
1,700 kPa
(17.0 kg/cm
2, 242 psi)

3 - 61
CHK
ADJ
3. Replace:
• blown fuse
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. Set the main switch to “OFF”.
b. Install a new fuse of the correct
amperage.
c. Set the main switch to “ON” and ver-
ify if the electrical circuit is opera-
tional.
d. If the fuse immediately blows again,
check the electrical circuit.
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
WARNINGWARNING
Never use a fuse with an amperage
other than that specified. Improvising or
using a fuse with the wrong amperage
rating may cause extensive damage to
the electrical system, cause the lighting
and ignition systems to malfunction
and could possibly cause a fire.
4. Install:
• rear cowling
Refer to “COWLINGS”.Item Amperage Q’ty
Main fuse 30 A 1
Headlight
fuse20 A 1
Signaling
system fuse20 A 1
Electronic
fuel injection
system fuse20 A 1
ECU fuse 7.5 A 1
Radiator
fan motor
fuse7.5 A 1
Backup fuse
(odometer)7.5 A 1
Reserve 30 A 1
Reserve 20 A 2
Reserve 7.5 A 2
CHECKING THE FUSES

ENG

4 - 5
ENGINE
Order Job/Part Q’ty Remarks
3 Crankcase breather hose 1
4 Ignition coil 4
5 Camshaft sensor 1
6 Starter motor lead 1 Disconnect.
7 Ground lead 1 Disconnect.
8 Starter motor 1
9 Pickup coil coupler 1 Disconnect.
10 Plastic clip 1
11 Stator coil assembly coupler 1 Disconnect.
12 Sidestand switch coupler 1
13 Oil level switch connector 1 Disconnect.
14 Neutral switch 1
For connecting, reverse the disconnec-
tion procedure.

8 - 1
–+ELEC

ELECTRICAL COMPONENTS
EB800000
ELECTRICAL
ELECTRICAL COMPONENTS
1
Wire harness
2
Main switch
3
Front brake light switch
4
Ignition coils
5
Clutch switch
6
Throttle position sensor
7
Intake air temperature sensor
8
Intake air pressure sensor
9
Atmospheric pressure sensor
0
Turn signal relay
A
Relay unit
B
ECU
C
CDI unit
D
Fuse box
E
Fall detection switch
F
Starter relay
G
Main fuse
H
Main relay
I
Battery
J
Rectifier/regulator
K
Rear brake light switch
L
Neutral switch
M
Speed sensor
N
Sidestand switch
O
Stator coil assembly
P
Oil level switch
Q
Pickup coil
R
Radiator fan
S
Horn
T
Coolant temperature
sender
U
Thermo switch
V
Camshaft sensor
8

8 - 7
–+ELECIGNITION SYSTEM
EB802001
IGNITION 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
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
B2
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
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G
H
X
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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
Gy
TCylinder #2-ignition coil
UCylinder #3-ignition coil
VCylinder #4-ignition coil
WCDI unit
ZNeutral switch
}Engine stop switch
£ECU fuse
1Main switch
5Battery
6Main switch
0Relay unit
ADiode
BSidestand switch
JECU
SCylinder #1-ignition coil

8 - 8
–+ELECIGNITION SYSTEM
TROUBLESHOOTING
C0NTINUITYOK
C0NTINUITYOK
C0NTINUITYOK
No good
C0NTINUITYOK
C0NTINUITYOK
C0NTINUITYOK
C0NTINUITYOK
C0NTINUITYOK
C0NTINUITYOK
C0NTINUITYOK
C0NTINUITYOK
C0NTINUITYOK The ignition system fails to operate (no spark or intermittent spark).
Check the main and ECU fuses for
continuity.Replace.
Check the condition of the bat-
tery.Recharge or replace.
Check the spark plug. Re-gap or replace.
Measure the ignition spark gap. Ignition system is OK.
Measure the ignition coil resis-
tance.Replace.
Measure the pickup coil resis-
tance.Replace.
Check the main switch. Replace.
Check the engine stop switch.Replace the right handlebar
switch.
Check the neutral switch. Replace.
Check the diode. Replace.
Check the sidestand switch. Replace.
Check the relay unit. Replace.
Check the entire ignition sys-
tem’s wiring.Repair or replace.
Replace the CDI unit.
No good
No good
No good
No good
No good
No good
No good
No good
No good
OK
No good
No good
No good