YAMAHA YZF-R7 1999 Owners Manual

8 - 5
–+ELECCHECKING THE BULBS AND BULB SOCKETS
WARNINGWARNING
Since the headlight bulb gets extremely
hot, keep flammable products and your
hands away from the bulb until it has
cooled down.
CAUTION:
• Be sure to hold the socket firmly when
removing the bulb. Never pull the lead,
otherwise it may be pulled out of the ter-
minal in the coupler.
• Avoid touching the glass part of the head-
light bulb to keep it free from oil, other-
wise 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.
2.Check:
• bulb (for continuity)
(with the pocket tester)
No continuity ® Replace.
NOTE:
Before checking for continuity, set the
pocket tester to “0” and to the “W ´ 1”
range.
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 t
a. Connect the tester positive probe to ter-
minal 1 and the tester negative probe to
terminal 2, and check the continuity.
b. Connect the tester positive probe to ter-
minal 1 and the tester negative probe to
terminal 3, and check the continuity.
c. If either of the readings indicate no conti-
nuity, replace the bulb.
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 s
Pocket tester
90890-03112

8 - 6
–+ELECCHECKING THE BULBS AND BULB SOCKETS
CHECKING THE CONDITION OF THE BULB
SOCKETS
The following procedure applies to all of
the bulb sockets.
1.Check:
• bulb socket (for continuity)
(with the pocket tester)
No continuity ® Replace.
NOTE:
Check each bulb socket for continuity in the
same manner as described in the bulb sec-
tion; however, note the following.
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 t
a. Install a good bulb into the bulb socket.
b. Connect the pocket tester probes to the
respective leads of the bulb socket.
c. Check the bulb socket for continuity. If
any of the readings indicate no continu-
ity, replace the bulb socket.
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 s
CHECKING THE LEDs
The following procedure applies to all of
the LEDs.
1.Check:
LED (for proper operation)
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 t
a. Disconnect the meter assembly coupler
(meter assembly side).
b. Connect two jumper leads 1 from the
battery terminals to the respective cou-
pler terminals as shown.
WARNINGWARNING
• A wire that is used as a jumper lead must
have at least the same capacity of the
battery lead, otherwise the jumper lead
may burn.
• This check is likely to produce sparks,
therefore make sure that no flammable
gas or fluid is in the vicinity.
c. When the jumper leads are connected to
the terminals the respective LED should
illuminate.
Does not light ® Replace the meter
assembly.
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 s
Pocket tester
90890-03112

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
gf f e dc b a` ] \[ FE DC
I
G
H
X
j k
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op
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t s
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1
Œ

 
£¢ ¤
¥
¦xy

(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

8 - 9
–+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)

8 - 10
–+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

8 - 11
–+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

8 - 12
–+ELECELECTRIC STARTING SYSTEM
EB803000
ELECTRIC STARTING 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
I
G
H
X
j k
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op
i w v u

t s
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1
Œ

 
£¢ ¤
¥
¦xy

(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
BBB2
GyBSidestand switch
JECU
ZNeutral switch
rClutch switch
}Engine stop switch
~Start switch
£ECU fuse
1Main switch
5Battery
6Main fuse
7Starter relay
8Starter motor
9Diode
0Relay unit
ADiode

8 - 13
–+ELECELECTRIC STARTING SYSTEM
TROUBLESHOOTING
C0NTINUITYOK
C0NTINUITYOK
C0NTINUITYOK
C0NTINUITYOK
C0NTINUITYOK
C0NTINUITYOK
C0NTINUITYOK
C0NTINUITYOK
C0NTINUITYOK
C0NTINUITYOK
C0NTINUITYOK
C0NTINUITYOK The starter motor fails to turn.
Check the main and ECU fuses for
continuity.Replace.
Check the condition of the bat-
tery.Recharge or replace.
Check the starter motor. Repair or replace.
Check the relay unit. Replace.
Check the starter relay. Replace.
Check the diodes. Replace.
Check the main switch. Replace.
Check the engine stop switch.Replace the right handlebar
switch.
Check the neutral switch. Replace.
Check the sidestand switch. Replace.
Check the clutch switch. Replace.
Check the start switch.Replace the right handlebar
switch.
Check the entire starting sys-
tem’s wiring.Repair or replace.
No good
No good
No good
No good
No good
No good
No good
No good
No good
No good
No good
No good
No good

8 - 14
–+ELECELECTRIC STARTING SYSTEM
NOTE:
• Before troubleshooting, remove the following part(-s):
1) fuel tank4) bottom cowling
2) air filter case5) front cowling
3) throttle body assembly6) rear cowling
• Troubleshoot with the following special tool(-s).
Pocket tester
90890-03112
CHECKING THE RELAY UNIT
• Disconnect the relay unit from the cou-
pler.
• Connect the pocket tester (W ´ 1) and bat-
tery (12 V) to the relay unit terminals as
shown.
• Does the starting circuit cutoff relay have
continuity between blue/white and black?
• Connect the pocket tester (W ´ 1) to the
relay unit terminals as shown.
• Check the relay unit for continuity as fol-
lows.
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. Battery positive terminal ® red/black 1
Battery negative terminal ®
black/yellow 2
Tester positive probe ® blue/white 3
Tester negative probe ® black 4
Tester positive probe ®
sky blue 5
Tester negative probe ®
black/yellow 2
Continu-
ity
Tester positive probe ®
sky blue 5
Tester negative probe ®
blue/yellow 6
Tester positive probe ®
black/yellow 2
Tester negative probe ®
sky blue 5
No conti-
nuity
Tester positive probe ®
blue/yellow 6
Tester negative probe ®
sky blue 5
R/B L/WW G
Lg
L/R L/BSbB/Y B B/R L/Y
6
1
3 54 2