ignition YAMAHA YZF-R7 1999 Owner's Manual

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–+ELECIGNITION SYSTEM
BAD
NOTE:
• Before troubleshooting, remove the following part(-s):
1) fuel tank
2) air filter case
3) bottom cowling
4) front cowling
5) rear cowling
• Troubleshoot with the following special tool(-s).
Replace the ECU.
Ignition checker
90890-06754
Pocket tester
90890-03112
MEASURING THE IGNITION SPARK GAP
The following procedure applies to all of
the spark plugs.
• Disconnect the ignition coil from the spark
plug.
• Connect the ignition checker 1 as shown.
2 Ignition coil
• Set the main switch to “ON”.
• Measure the ignition spark gap a.
• Crank the engine by pushing the start
switch and gradually increase the spark
gap until a misfire occurs.
• Is there a spark and is the spark gap
within specification?
Yes ® Good.
No ® Measure the ignition coil resistance.
Minimum ignition spark gap
6 mm (0.24 in)

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–+ELECIGNITION SYSTEM
MEASURING THE IGNITION COIL
RESISTANCE
The following procedure applies to all of
the ignition coils.
• Remove the ignition coil from the cylinder
head.
• Connect the pocket tester (W ´ 1) to the
ignition coil as shown.
• Measure the primary coil resistance.
• Connect the pocket tester (W ´ 1k) to the
ignition coil as shown.
• Measure the secondary coil resistance.
• Is the ignition coil OK?
Yes ® Good.
No ® Replace.
MEASURING THE PICKUP COIL
RESISTANCE
• Disconnect the pickup coil coupler from
the wire harness.
• Connect the pocket tester (W ´ 100) to the
pickup coil coupler.
• Measure the pickup coil resistance.
• Is the pickup coil OK?
Yes ® Good.
No ® Replace. Tester positive probe ®
orange (cylinder #1) 1
gray (cylinder #2)
gray/green (cylinder #3)
orange/green (cylinder #4)
Tester negative probe ® black 2
Primary coil resistance
0.16 ~ 0.21 W at 20˚C (68˚F)
Tester positive probe ®
orange (cylinder #1) 1
gray (cylinder #2)
gray/green (cylinder #3)
orange/green (cylinder #4)
Tester negative probe ®
ignition coil hole 3
Secondary coil resistance
5.0 ~ 6.8 kW at 20˚C (68˚F)
Tester positive probe ® gray 1
Tester negative probe ® black 2
Pickup coil resistance
421 ~ 569 W at 20˚C (68˚ F)
(between gray and black)
3
1
2

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–+ELEC
CHECKING THE DIODE
• Remove the diode from the coupler.
• Connect the pocket tester (W ´ 1) to the
diode as shown.
• Check the diode for continuity.
NOTE:
When you switch the tester’s positive and
negative probes, the readings in the above
chart will be reversed.
• Are the tester readings correct?
Yes ® Good.
No ® Replace. Tester positive probe ®
blue/white 1
Tester negative probe ®
blue/yellow 2Continu-
ity
Tester positive probe ®
blue/yellow 2
Tester negative probe ®
blue/white 1No conti-
nuity
L/W
L/Y
1
2
CHECKING THE RELAY UNIT
• Remove the relay unit from the coupler.
• Connect the pocket tester (W ´ 1) to the
relay unit terminals as shown.
• Check the starting circuit cutoff relay for
continuity.
NOTE:
When you switch the tester’s positive and
negative probes, the readings in the above
chart will be reversed.
• Are the tester readings correct?
Yes ® Good.
No ® Replace. Tester positive probe ®
sky blue 1
Tester negative probe ®
blue/yellow 2Continu-
ity
Tester positive probe ®
blue/yellow 2
Tester negative probe ®
sky blue 1No conti-
nuity
R/B L/WW G
Lg
L/R L/BSbB/Y B B/R L/Y
21
IGNITION SYSTEM

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–+ELECCHARGING SYSTEM
MEASURING THE CHARGING VOLTAGE
• Connect the engine tachometer to the
ignition coil of cylinder #1.
Refer to “SYNCHRONIZING THE THROT-
TLE BODIES” in chapter 3.
• Connect the pocket tester (DC 20V) to the
battery as shown.
• Start the engine and let it run at approxi-
mately 1,100 r/min.
• Measure the charging voltage.
NOTE:
• Make sure that the battery is fully
charged.
• When measuring, turn off the headlights
and make sure that no load is applied.
• Is the charging voltage within specifica-
tion?
Yes ® OK.
No ® Measure the stator coil assembly
resistance. Tester positive probe ®
battery positive terminal
Tester negative probe ®
battery negative terminal
Charging voltage
12 V at 1,100 r/min
MEASURING THE STATOR COIL
ASSEMBLY RESISTANCES
• Disconnect the generator coupler from
the wire harness.
• Connect the pocket tester (W ´ 1) to the
stator coil assembly coupler as shown.
• Measure the stator coil assembly resis-
tances.
• Is the stator coil assembly OK?
Yes ® OK.
No ® Replace. Tester positive probe ® white 1
Tester negative probe ® white 2
Tester positive probe ® white 1
Tester negative probe ® white 3
Stator coil resistance
0.38 ~ 0.46 W at 20˚C (68 ˚F)

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–+ELECELECTRICAL CONTROL SYSTEM
ELECTRICAL CONTROL SYSTEM
The YZF-R7 features an electrical control system with the following modes:
• user mode
• diagnosis mode
• CO emission adjustment mode
NOTE:
The vehicle is normally in user mode. Special tools are needed to switch to a diagnosis mode
or to the CO emission adjustment mode.
USER MODE
• If a circuit is defective, setting the main switch to “ON” (without starting the engine) will
cause the corresponding condition code to be displayed by the tachometer, the warning
light to light up, and the engine trouble symbol to blink. When the engine is started, the
condition code is no longer displayed and the engine speed appears.
• Normally, when the main switch is set to “ON”, the warning light comes on for 1.4 seconds
and then goes off. The warning light also comes on while the start switch is pushed.
• When the engine is not running, the warning light flashes once every 0.16 second if the start
switch is pushed under the following conditions.
• The fall detection switch switches off the main relay.
• Ignition is cut off by the sidestand switch.
• The injector operating voltage decreases to 3 V or less, or the main relay malfunctions.
• The pickup coil is defective.
• The fall detection switch is defective.

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–+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.

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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)

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