light YAMAHA YZF-R7 1999 Owner's Guide

6 - 13
EFIELECTRONIC FUEL INJECTION
3. Adjust:
• throttle position sensor angle
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a. Disconnect the throttle position sen-
sor coupler from the throttle position
sensor.
b. Connect the pocket tester (W ´ 1k) to
the throttle position sensor.
c. Measure the throttle position sensor
maximum resistance.
d. Calculate the throttle position sensor
maximum resistance when the throt-
tle is fully closed.
Example:
If the maximum resistance = 5 kW, then
the throttle position sensor’s maximum
resistance when the throttle is fully
closed should be:
5 kW ´ (0.13 ~ 0.15) = 650 ~ 750 W
Lift the throttle body assembly slightly
out of the intake manifolds.
Loosen the throttle position sensor
screws 4.
Connect the pocket tester (W ´ 100) to
the throttle position sensor.
e. Adjust the throttle position sensor
angle so that the measured resistance
is within the specified range.
After adjusting the throttle position sen-
sor angle, tighten the throttle position
sensor screws.
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Positive tester probe ®
blue terminal 1
Negative tester probe ®
black/blue terminal 2
Throttle position sensor maximum
resistance (throttle is fully closed) =
Maximum resistance ´ (0.13 ~ 0.15)
Positive tester probe ®
yellow terminal 3
Negative tester probe ®
black/blue terminal 2
Throttle position sensor resis-
tance
650 ~ 750 W
(yellow — black/blue)
B/LYL
231
4

4

7 - 8
CHASFRONT WHEEL AND BRAKE DISCS
3. Adjust:
• front wheel static balance
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a. Install a balancing weight 1 onto the
rim exactly opposite the heavy spot
“X”.
NOTE:
Start with the lightest weight.
b. Turn the front wheel 90˚ so that the
heavy spot is positioned as shown.
c. If the heavy spot does not stay in that
position, install a heavier weight.
d. Repeat steps (b) and (c) until the front
wheel is balanced.
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4. Check:
• front wheel static balance
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a. Turn the front wheel and make sure
that it stays at each position shown.
b. If the front wheel does not remain
stationary at all of the positions,
rebalance it.
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7 - 42
CHASFRONT AND REAR BRAKES
2. Fill:
• brake fluid reservoir
WARNINGWARNING
• Use only the designated brake fluid.
Other brake fluids may cause the rub-
ber seals to deteriorate, causing leak-
age and poor brake performance.
• Refill with the same type of brake fluid
that is already in the system. Mixing
brake fluids may result in a harmful
chemical reaction, leading to poor
brake performance.
• When refilling, be careful that water
does not enter the reservoir. Water
will significantly lower the boiling
point of the brake fluid and could
cause vapor lock.
ACHTUNG:CAUTION:
Brake fluid may damage painted sur-
faces and plastic parts. Therefore,
always clean up any spilt brake fluid
immediately.
3. Bleed:
• brake system
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
Recommended brake fluid
DOT 4
4. Check:
• brake fluid level
Below the minimum level mark a ®
Add the recommended brake fluid to
the proper level.
Refer to “CHECKING THE BRAKE
FLUID LEVEL” in chapter 3.
5. Adjust:
• brake pedal position
Refer to “ADJUSTING THE REAR
BRAKE” in chapter 3.
6. Adjust:
• rear brake light operation timing
Refer to “ADJUSTING THE REAR
BRAKE LIGHT SWITCH” in chapter 3.

7 - 58
CHAS
EB703100
REMOVING THE FRONT FORK LEGS
The following procedure applies to both of
the front fork legs.
1. Stand the motorcycle on a level surface.
WARNINGWARNING
Securely support the motorcycle so that
there is no danger of it falling over.
NOTE:
Place the motorcycle on a suitable stand
so that the front wheel is elevated.
2. Adjust:
• spring preload
NOTE:
Turn the adjusting bolt 1 in fully so that
it sits lightly. Refer to “ADJUSTING THE
FRONT FORK LEGS” in chapter 3.
1
1

3. Loosen:
• upper bracket pinch bolt 1
• cap bolt 2
(with the front fork cap bolt wrench)
• handlebar pinch bolts
• lower bracket pinch bolts
WARNINGWARNING
Before loosening the upper and lower
bracket pinch bolts and handlebar pinch
bolt, support the front fork leg.
4. Remove:
• front fork leg
Front fork cap bolt wrench:
90890-01472
1
1
2

2

EB703113
DISASSEMBLING THE FRONT FORK LEGS
The following procedure applies to both of
the front fork legs.
1. Remove:
• cap bolt 1
(from the damper rod assembly)
• straight key
• washer
• damper adjusting rod
4
51
2
3
FRONT FORK

7 - 65
CHAS
c. Install the fork spring, spacer, spring
seat and nut.
NOTE:
Finger tighten the nut onto the winding
at the damper rod end.
d. Install the rod puller and adapter onto
the damper rod.
e. Press down on the spacer with the
fork spring compressor 9.
f. Pull up the rod puller and install the
rod holder 0 between the nut 4 and
the spring seat.
NOTE:
Use the side of the rod holder that is
marked “A”.
g. Remove the rod puller and adapter.
h. Install the damper adjusting rod,
washer, straight key and cap bolt, and
then finger tighten the cap bolt.
NOTE:
• Make sure that the spring preload
adjusting bolt at the top of cap bolt is
fully, but lightly tightened.
• Insert the cap bolt fully into the
damper rod.
i. Hold the cap bolt and tighten the nut.
j. Remove the rod holder and fork
spring compressor.
WARNINGWARNING
• The fork spring is compressed.
• Always use a new cap bolt O-ring.
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Rod puller
90890-01437
Adapter
90890-01436
Fork spring compressor
90890-01441
Rod holder
90890-01434
T R..
Nut
25 Nm (2.5 m • kg, 18 ft • lb)
9
0
4
FRONT FORK

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 - 3
–+ELEC

CHECKING THE SWITCHES
EB801010
CHECKING THE SWITCHES
Check each switch for damage or wear, proper connections, and also for continuity between
the terminals. Refer to “CHECKING SWITCH CONTINUITY”.
Damage/wear
® Repair or replace the switch.
Improperly connected ® Properly connect.
Incorrect continuity reading ® Replace the switch.
1Main switch
2Light switch
3Pass switch
4Dimmer switch
5Turn signal switch6Horn switch
7Clutch switch
8Engine stop switch
9Start switch
0Front brake light switchAOil level switch
BRear brake light switch
CFuse
DNeutral switch
ESidestand switch
1L/YL/B
LL/R
R
Br/L
OFF
ONP
L/RLBr/LRL/YL/B
3
4
5
Br/WR/YPLB
Dg Y
G Ch
B/YL/YPASS—
R/YY
67
YG
—BP
(BLUE)
(BLACK)
(BLACK)
R/WBr
R/BB
G/YL/W
B
B
G/YBr
OFF
ChBr/WDg
8R/WR/B
9
0—L/WB
2R/YL•
C
E
(BLUE)
B
B
B D
(BROWN)
Sb
A
W
L/YB/Y
L/YB/Y

8 - 4
–+ELECCHECKING THE BULBS AND BULB SOCKETS
EB801020
CHECKING THE BULBS AND
BULB SOCKETS
Check each bulb and bulb socket for dam-
age or wear, proper connections, and also
for continuity between the terminals.
Damage/wear ® Repair or replace the
bulb, bulb socket or both.
Improperly connected ® Properly con-
nect.
Incorrect continuity reading ® Repair or
replace the bulb, bulb socket or both.
TYPES OF BULBS
The bulbs used on this motorcycle are
shown in the illustration on the left.
• Bulbs A and B are used for headlights
and usually use a bulb holder which must
be detached before removing the bulb.
The majority of these bulbs can be
removed from their respective socket by
turning them counterclockwise.
• Bulb C is used for turn signal and tail/
brake lights and can be removed from the
socket by pushing and turning the bulb
counterclockwise.
• Bulbs
D and E are used for meter and
indicator lights and can be removed from
their respective socket by carefully pulling
them out.
CHECKING THE CONDITION OF THE BULBS
The following procedure applies to all of
the bulbs.
1.Remove:
• bulb

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.
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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.
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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.
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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.
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CHECKING THE LEDs
The following procedure applies to all of
the LEDs.
1.Check:
LED (for proper operation)
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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.
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Pocket tester
90890-03112