light YAMAHA YZF-R7 1999 Owner's Manual

3 - 55
CHK
ADJ
EB305020
ELECTRICAL SYSTEM
CHECKING AND CHARGING THE BATTERY
WARNINGWARNING
Batteries generate explosive hydrogen
gas and contain electrolyte which is
made of poisonous and highly caustic
sulfuric acid.
Therefore, always follow these preven-
tive measures:
• Wear protective eye gear when han-
dling or working near batteries.
• Charge batteries in a well-ventilated
area.
• Keep batteries away from fire, sparks
or open flames (e.g., welding equip-
ment, lighted cigarettes).
• DO NOT SMOKE when charging or
handling batteries.
• KEEP BATTERIES AND ELECTROLYTE
OUT OF REACH OF CHILDREN.
• Avoid bodily contact with electrolyte
as it can cause severe burns or perma-
nent eye injury.
FIRST AID IN CASE OF BODILY CON-
TACT:
EXTERNAL
• Skin – Wash with water.
• Eyes – Flush with water for 15 minutes
and get immediate medical attention.
INTERNAL
• Drink large quantities of water or milk
followed with milk of magnesia,
beaten egg or vegetable oil. Get
immediate medical attention.
ACHTUNG:CAUTION:
• This is a sealed battery. Never remove
the sealing caps because the balance
between cells will not be maintained
and battery performance will deterio-
rate.
• Charging time, charging amperage
and charging voltage for an MF bat-
tery are different from those of con-
ventional batteries. The MF battery
should be charged as explained in the
charging method illustrations. If the
battery is overcharged, the electrolyte
level will drop considerably. There-
fore, take special care when charging
the battery.
CHECKING AND CHARGING THE BATTERY

3 - 61
CHK
ADJ
3. Replace:
• blown fuse
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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

3 - 62
CHK
ADJ
REPLACING THE HEADLIGHT BULBS
EB305051
REPLACING THE HEADLIGHT BULBS
The following procedure applies to both of
the headlight bulbs.
1. Disconnect:
• headlight coupler 1
1
1

2. Remove:
• headlight bulb 1
WARNINGWARNING
Since the headlight bulb gets extremely
hot, keep flammable products and your
hands away from the bulb until it has
cooled down.
1
1

3. Install:
• headlight bulb
Secure the new headlight bulb with
the headlight bulb holder.
ACHTUNG:CAUTION:
Avoid touching the glass part of the
headlight bulb to keep it free from oil,
otherwise the transparency of the glass,
the life of the bulb and the luminous
flux will be adversely affected. If the
headlight bulb gets soiled, thoroughly
clean it with a cloth moistened with
alcohol or lacquer thinner.
4. Connect:
• headlight coupler
New

3 - 63
CHK
ADJ
ADJUSTING THE HEADLIGHT BEAMS
EB305061
ADJUSTING THE HEADLIGHT BEAMS
The following procedure applies to both of
the headlights.
1. Adjust:
• headlight beam (vertically)
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a. Turn the adjusting screw 1 in direc-
tion a or b.
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 aHeadlight beam is raised.
Direction bHeadlight beam is low-
ered.
2. Adjust:
• headlight beam (horizontally)
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a. Turn the adjusting screw 1 in direc-
tion a or b.
Left headlight
Right headlight
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 aHeadlight beam moves
to the right.
Direction bHeadlight beam moves
to the left.
Direction aHeadlight beam moves
to the left.
Direction bHeadlight beam moves
to the right.

4 - 14
ENGCAMSHAFTS
2. Check:
• camshaft sprocket
More than 1/4 tooth wear a ® Replace
the camshaft sprockets and the timing
chain as a set.
a1/4 tooth
bCorrect
1Timing chain roller
2Camshaft sprocket
3. Check:
• timing chain guide (exhaust side) 1
• timing chain guide (intake side) 2
• timing chain guide (top side) 3
Damage/wear ® Replace the defective
part(-s).
EB401430
CHECKING THE TIMING CHAIN
TENSIONER
1. Check:
• timing chain tensioner
Cracks/damage/rough movement ®
Replace.
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a. Lightly press the timing chain ten-
sioner rod into the timing chain ten-
sioner housing by hand.
NOTE:
While pressing the timing chain ten-
sioner rod, wind it clockwise with a thin
screwdriver 1 until it stops.
b. Remove the screwdriver and slowly
release the timing chain tensioner
rod.
c. Make sure that the timing chain ten-
sioner rod comes out of the timing
chain tensioner housing smoothly. If
there is rough movement, replace the
timing chain tensioner.
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4 - 16
ENGCAMSHAFTS
4. Install:
• timing chain guide (exhaust side)
5. Install:
• timing chain tensioner
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. Lightly press the timing chain ten-
sioner rod into the timing chain ten-
sioner housing by hand.
b. While pressing the timing chain ten-
sioner rod, wind it clockwise with a
thin screwdriver 1 until it stops.
c. With the screwdriver still inserted
into the timing chain tensioner, install
the timing chain tensioner and gasket
onto the cylinder block. Then, tighten
the timing chain tensioner bolts to the
specified torque.
WARNINGWARNING
Always use a new gasket.
NOTE:
The “UP” mark on the timing chain ten-
sioner should face up.
d. Remove the screwdriver, make sure
that the timing chain tensioner rod
releases, and tighten the cap bolt to
the specified torque.
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T R..
Timing chain tensioner bolt
10 Nm (1.0 m • kg, 7.2 ft • lb)
T R..
Cap bolt
10 Nm (1.0 m • kg, 7.2 ft • lb)
6. Turn:
• crankshaft
(several turns counterclockwise)

4 - 27
ENGVALVES AND VALVE SPRINGS
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a. Apply Mechanic’s blueing dye
(Dykem) b onto the valve face.
b. Install the valve into the cylinder
head.
c. Press the valve through the valve
guide and onto the valve seat to make
a clear impression.
d. Measure the valve seat width.
NOTE:
Where the valve seat and valve face con-
tacted one another, the blueing will have
been removed.
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4. Lap:
• valve face
• valve seat
NOTE:
After replacing the cylinder head or
replacing the valve and valve guide, the
valve seat and valve face should be
lapped.
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a. Apply a coarse lapping compound a
to the valve face.
ACHTUNG:CAUTION:
Do not let the lapping compound enter
the gap between the valve stem and the
valve guide.
b. Apply molybdenum disulfide oil onto
the valve stem.
c. Install the valve into the cylinder
head.
d. Turn the valve until the valve face and
valve seat are evenly polished, then
clean off all of the lapping compound.
NOTE:
For the best lapping results, lightly tap
the valve seat while rotating the valve
back and forth between your hands.

4 - 31
ENG

VALVES AND VALVE SPRINGS
4. Install:
• valve cotters
1
NOTE:

Install the valve cotters by compressing
the valve spring with the valve spring
compressor
2
and attachment
3
.
5. To secure the valve cotters
1
onto the
valve stem, lightly tap the valve tip with
a soft-face hammer.
ACHTUNG:CAUTION:

Hitting the valve tip with excessive
force could damage the valve.
Valve spring compressor
90890-04019
Attachment
(for the intake valve spring)
9080-04114
(for the exhaust valve spring)
90890-04108
6. Lubricate:
• valve pad
(with the recommended lubricant)
Recommended lubricant
Molybdenum disulfide oil
7. Install:
• valve pad
• valve lifter
NOTE:

• The valve lifter must move smoothly
when rotated with a finger.
• Each valve lifter and valve pad must be
reinstalled in its original position.

6 - 11
EFI

ELECTRONIC FUEL INJECTION
d. Connect the pocket tester (
W

´
1k) to
the throttle position sensor.
e. While slowly opening the throttle,
check that the throttle position sensor
resistance is within the specified
range.
NOTE:

Check mainly that the resistance
changes gradually when turning the
throttle, since the readings (from closed
to wide-open throttle) may differ slightly
from those specified.
Out of specification or the resistance
changes abruptly
®
Go to step 2
below.
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Positive tester probe
®

yellow terminal
3
Negative tester probe
®

black/blue terminal
2
Throttle position sensor resis-
tance
(520 ~ 900
W
) ~ (4.0 ~ 6.0 k
W
)
at 20 ˚C (68 ˚F)
(yellow — black/blue)
2. Check:
• throttle position sensor
(removed from the throttle body)
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a. Disconnect the throttle position sen-
sor coupler from the throttle position
sensor.
b. Remove the throttle position sensor
from the throttle body.
c. Connect the pocket tester (
W

´
1k) to
the throttle position sensor.
Positive tester probe
®

blue terminal
1
Negative tester probe
®

black/blue terminal
2
B/LYL
231

6 - 12
EFI

ELECTRONIC FUEL INJECTION
d. Measure the maximum throttle posi-
tion sensor resistance.
Out of specification
®
Replace the
throttle position sensor.
e. Connect the pocket tester (
W

´
1k) to
the throttle position sensor.
f. While slowly opening the throttle,
check that the throttle position sensor
resistance is within the specified
range.
The resistance does not change or it
changes abruptly
®
Replace the
throttle position sensor.
The slot is worn or broken
®
Replace
the throttle position sensor.
NOTE:

Check mainly that the resistance
changes gradually when turning the
throttle, since the readings (from closed
to wide-open throttle) may differ slightly
from those specified.
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
Maximum throttle position
sensor resistance
4.0 ~ 6.0 k
W
at 20 ˚C (68 ˚F)
(blue — black/blue)
Positive tester probe
®

yellow terminal
3
Negative tester probe ®
black/blue terminal 2
Throttle position sensor resis-
tance
0 ~ 5 ± 1.0 kW at 20 ˚C (68 ˚F)
(yellow — black/blue)