lock YAMAHA YZF-R7 1999 Workshop Manual

7 - 54
CHAS
• When refilling, be careful that water
does not enter the reservoir. Water
will significantly lower the boiling
point of the clutch fluid and could
cause vapor lock.
ACHTUNG:CAUTION:
Clutch fluid may damage painted sur-
faces or plastic parts. Therefore, always
clean up any spilt clutch fluid immedi-
ately.
3. Bleed:
• clutch system
Refer to “BLEEDING THE HYDRAULIC
CLUTCH SYSTEM” in chapter 3.
4. Check:
• clutch fluid level
Below the minimum level mark a ®
Add the recommended clutch fluid to
the proper level.
Refer to “CHECKING THE CLUTCH
FLUID LEVEL” in chapter 3.
5. Check:
• clutch lever operation
Soft or spongy feeling ® Bleed the
clutch system.
Refer to “BLEEDING THE HYDRAULIC
CLUTCH SYSTEM” in chapter 3.
aa
HYDRAULIC CLUTCH

7 - 72
CHAS
EB705001
STEERING HEAD
T R..13 Nm (1.3 m • kg, 9.4 ft • Ib)
T R..115 Nm (11.5 m • kg, 85 ft • Ib)
T R..18 Nm (1.8 kg •
m, 13 ft •
Ib)
9 Nm (0.9 kg
•
m, 6.5 ft •
Ib)
1st.
2nd.T R..19 Nm (1.9 m • kg, 13 ft • Ib)
LS1842
2 5
6
1 8
9
11
13
14
15
1810
3 16
14
17
12
7
20
LS
LS
19
Order Job/Part Q’ty Remarks
Removing the lower bracketRemove the parts in the order listed.
Front wheel Refer to “FRONT WHEEL AND BRAKE
DISCS”.
Front fork legs Refer to “FRONT FORK”.
1 Main switch coupler 2 Disconnect.
2 Upper bracket bolt 2
3 Left handlebar assembly 1
4 Right handlebar assembly 1
5 Steering stem nut 1
6 Upper bracket 1
7 Brake hose holder bolt 2
8 Lock washer 1
9 Upper ring nut 1
10 Rubber washer 1
STEERING HEAD

7 - 75
CHAS
EB705700
INSTALLING THE STEERING HEAD
1. Lubricate:
• upper bearing
• lower bearing
• bearing races
• O-ring
• dust seat lips
• bearing cover lips
• steering stem shreads
2. Install:
• lower ring nut 1
• rubber washer 2
• upper ring nut 3
• lock washer 4
Refer to “CHECKING AND ADJUSTING
THE STEERING HEAD” in chapter 3.
Recommended lubricant
Lithium soap base grease
3. Install:
• upper bracket
• steering stem nut
NOTE:
Temporarily tighten the steering stem
nut.
4. Install:
• front fork legs
Refer to “FRONT FORK”.
NOTE:
Temporarily tighten the upper and lower
bracket pinch bolts, and handlebar pinch
bolts.
5. Tighten:
• steering stem nut
• lower bracket pinch bolt
• upper bracket pinch bolt

• upper bracket bolt
• handlebar pinch bolt
T R..115 Nm (11.5 m · kg, 85 ft · lb)
T R..11 Nm (1.1 m · kg, 8.0 ft · lb)
T R..26 Nm (2.6 m · kg, 19 ft · lb)
T R..13 Nm (1.3 m · kg, 9.4 ft · lb)
T R..13 Nm (1.3 m · kg, 9.4 ft · lb)
STEERING HEAD

7 - 76
CHAS
EB706000
REAR SHOCK ABSORBER ASSEMBLY
Order Job/Part Q’ty Remarks
Removing the rear shock absorber
assemblyRemove the parts in the order listed.
1 Bolt 1
2 Self-locking nut/bolt 1/1
3 Self-locking nut/bolt 2/2
4 Self-locking nut/bolt 1/1
5 Rear shock absorber assembly 1
6 Self-locking nut/bolt 1/1
7 Connecting arm 2
8 Spacer/oil seal/bearing2/4/2
9 Sidestand 1
10 Self-locking nut/bolt/spacer1/1/1
11 Relay arm 1
12 Spacer/oil seal/bearing3/6/3
For installation, reverse the removal
procedure.
REAR SHOCK ABSORBER ASSEMBLY

7 - 80
CHAS
EB707000
SWINGARM AND DRIVE CHAIN
Order Job/Part Q’ty Remarks
Removing the swingarm and drive
chainRemove the parts in the order listed.
Drive sprocket Refer to “ENGINE” in chapter 4.
Rear wheel Refer to “REAR WHEEL, BRAKE DISC,
AND REAR WHEEL SPROCKET”.
Rear shock absorber assembly Refer to “REAR SHOCK ABSORBER
ASSEMBLY”.
1 Spacer 1
2 Adjusting bolt/locknut 2/2
3 Left drive chain puller 1
4 Right drive chain puller 1
5 Drive chain guard 1 1
6 Drive chain guard 3 1
7 Brake hose holder 3
8 Pivot shaft nut/washer 1/1
9 Right pivot shaft boss 1
SWINGARM AND DRIVE CHAIN

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 - 26
–+ELECCOOLING SYSTEM
CHECKING THE THERMO SWITCH
• Remove the thermo switch from the radia-
tor.
• Connect the pocket tester (W ´ 1) to the
thermo switch 1 as shown.
• Immerse the thermo switch in a container
filled with coolant 2.
NOTE:
Make sure that the thermo switch terminals
do not get wet.
• Place a thermometer 3 in the coolant.
• Slowly heat the coolant, then let it cool to
the specified temperature as indicted in
the table.
• Check the thermo switch for continuity a
the temperatures indicated in the table.
WARNINGWARNING
• Handle the thermo switch with special
care.
• Never subject the thermo switch to
strong shocks. If the thermo switch is
dropped, replace it.
The thermo switch circuit is open and the
radiator fan is off.
õThe thermo switch circuit is closed and the
radiator fan is on.
• Does the thermo switch operate properly
as described above?
Yes ® OK.
No ® Replace.
Test stepCoolant temperature
Continuity
Thermo switch
10 ~ 100 ± 3˚C
(0 ~ 212 ± 37.4˚F)NO
2
More than 105 ± 3˚C
(221 ± 37.4˚C)YES
3*
105 to 100 ˚C
(221 to 212 ˚F)YES
4*
Less than 100 ˚C (212 ˚F)NO
Test steps 1 & 2: Heating phase
Test steps 3* & 4*: Cooling phase
T R..
Thermo switch
23 Nm (2.3 m • kg, 17 ft • lb)
Three bond sealock
® 10

8 - 32
–+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.

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