ECU YAMAHA YZF-R7 1999 Owners Manual

ELECTRICAL SPECIFICATIONSSPEC
2 - 16
Electric starting system
System type Constant mesh ----
Starter motor
Model (manufacturer) SM-14 (MITSUBA) ----
Power output 0.6 kW ----
Armature coil resistance 0.0015 ~ 0.0025 W----
Brushes
Overall length 10 mm (0.40 in) 3.5 mm
(0.14 in)
Spring force 7.16 ~ 9.52 N
(730 ~ 971 gf, 25.8 ~ 34.3 oz)----
Commutator resistance 0.025 ~ 0.035 W----
Commutator diameter 28 mm (1.10 in) 27 mm
(1.06 in)
Mica undercut 0.7 mm (0.03 in) ----
Starter relay
Model (manufacturer) MS5F-631 (JIDECO) ----
Amperage 180 A ----
Coil resistance 4.18 ~ 4.62 W ----
Horn
Horn type Plain ----
Model (manufacturer) ´ quantity YF-12 (NIKKO) ´ 1 ----
Max. amperage 3 A ----
Turn signal relay
Relay type Full-transistor ----
Model (manufacturer) FE246BH (DENSO) ----
Self-cancelling device built-in No ----
Turn signal blinking frequency 75 ~ 95 cycles/min. ----
Wattage 21 W ´ 2 + 3.4 W ----
Oil level switch model (manufac-
turer)071380-0480 (DENSO) ----
Fuel pump relay model (manufac-
turer)G8R-30Y-J (OMRON) ----
Thermo switch model (manufac-
turer)5EB (NIPPON THERMOSTAT) ----
Fuses (amperage ´ quantity)
Main fuse 30 A ´ 1 ----
Headlight fuse 20 A ´ 1 ----
Signaling system fuse 20 A ´ 1 ----
EFI fuse 20 A ´ 1 ----
ECU fuse 7.5 A ´ 1 ----
Radiator fan fuse 7.5 A ´ 1 ----
Backup fuse (odometer) 7.5 A ´ 1 ---- Item Standard Limit

2 - 30
SPEC
1Ignition coil
2Throttle position sensor coupler
3Camshaft sensor
4Injector 1 coupler
5Starter motor
6Fuel tank overflow hose
7Fuel pump coupler
8Rectifier/regurator
9Battery
0Turn signal relayAECU
BFuse box
CFall detection switch
DStarter relay
EMain relay
FThrottle stop screw cable
GFuel tank breather hose
HAir filter case breather hose
IIntake air temperature sensor coupler
JInjector 2 sub-lead
CABLE ROUTING

3 - 41
CHK
ADJADJUSTING THE SHIFT PEDAL/
ADJUSTING THE DRIVE CHAIN SLACK
EB304081
ADJUSTING THE SHIFT PEDAL
NOTE:
The shift pedal position is determined
by the installed shift rod length a.
1. Measure:
• installed shift rod length a
Incorrect ® Adjust.
2. Adjust:
• installed shift rod length a
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. Loosen both locknuts 1.
b. Turn the shift rod 2 in direction b or
c to obtain the correct shift pedal
position.
c. Tighten both locknuts.
d. Make sure that the installed shift rod
length is within specification.
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
Installed shift rod length
294 mm (11.57 in)
Direction bInstalled shift rod length
decreases.
Direction cInstalled shift rod length
increases.
1
1
1
1
a a
b bc
c
EB304092
ADJUSTING THE DRIVE CHAIN SLACK
NOTE:
The drive chain slack must be checked at
the tightest point on the chain.
ACHTUNG:CAUTION:
A drive chain that is too tight will over-
load the engine and other vital parts,
and one that is too loose can skip and
damage the swingarm or cause an acci-
dent. Therefore, keep the drive chain
slack within the specified limits.
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 rear wheel is elevated.

3 - 43
CHK
ADJLUBRICATING THE DRIVE CHAIN/
CHECKING AND ADJUSTING THE STEERING HEAD
EB304100
LUBRICATING THE DRIVE CHAIN
The drive chain consists of many interact-
ing parts. If the drive chain is not main-
tained properly, it will wear out rapidly.
Therefore, the drive chain should be ser-
viced, especially when the motorcycle is
used in dusty areas. This motorcycle has a
drive chain with small rubber O-rings
between each side plate. Steam cleaning,
high-pressure washing, certain solvents,
and the use of a coarse brush can damage
these O-rings. Therefore, use only kerosine
to clean the drive chain. Wipe the drive
chain dry and thoroughly lubricate it with
engine oil or chain lubricant that is suitable
for O-ring chains. Do not use any other
lubricants on the drive chain since they may
contain solvents that could damage the O-
rings.
Recommended lubricant
Engine oil or chain lubricant
suitable for O-ring chains
EB304130
CHECKING AND ADJUSTING THE
STEERING HEAD
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. Check:
• steering head
Grasp the bottom of the front fork legs
and gently rock the front fork.
Looseness/binding ® Adjust the steer-
ing head.

3 - 46
CHK
ADJCHECKING AND ADJUSTING THE STEERING HEAD/
CHECKING THE FRONT FORK
d. Hold the spring gauge at a 45˚ angle
from the handlebar, pull the spring
gauge, and record the measurement
when the handlebar starts to turn.
e. Repeat the above procedure on the
opposite handlebar.
f. If the steering head tension is out of
specification (both handlebars should
be within specification), remove the
upper bracket and loosen or tighten
the upper ring nut.
g. Reinstall the upper bracket and mea-
sure the steering head tension again
as described above.
h. Repeat the above procedure until the
steering head tension is within speci-
fication.
i. Grasp the bottom of the front fork
legs and gently rock the front fork.
Looseness or binding ® Adjust the
steering head.
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
Steering head tension
200 ~ 500 g (7.06 ~ 17.65 oz)
EB304141
CHECKING THE FRONT FORK
1. Stand the motorcycle on a level surface.
WARNINGWARNING
Securely support the motorcycle so that
there is no danger of it falling over.
2. Check:
• inner tube 1
Damage/scratches ® Replace.
• dust seal 2
• oil seal
Oil leakage ® Replace.
3. Hold the motorcycle upright and apply
the front brake.
4. Check:
• front fork operation
Push down hard on the handlebars
several times and check if the front
fork rebounds smoothly.
Rough movement ® Repair.
Refer to “FRONT FORK” in chapter 7.

3 - 47
CHK
ADJ
ADJUSTING THE FRONT FORK LEGS
EB304153
ADJUSTING THE FRONT FORK LEGS
The following procedure applies to both of
the front fork legs.
WARNINGWARNING
• Always adjust both front fork legs
evenly. Uneven adjustment can result
in poor handling and loss of stability.
• Securely support the motorcycle so
that there is no danger of it falling
over.
Spring preload
ACHTUNG:CAUTION:
• Grooves are provided to indicate the
adjustment position.
• Never go beyond the maximum or
minimum adjustment positions.
1. Adjust:
• spring preload
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. Turn the adjusting bolt 1 in direction
a or b.
NOTE:
With each turn of the adjusting bolt, the
installed length of the fork spring is
changed by 1 mm.
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 a
(turns in)Spring preload is
increased (suspension is
harder).
Direction b
(turns out)Spring preload is
decreased (suspension is
softer).
Adjusting positions
Minimum: 0 turns in direction*
Standard: 14 turns in direction*
Maximum: 18-1/2 turns in direction*
* after fully turning the adjusting
bolt in direction b
1
1

a a
b b

3 - 49
CHK
ADJ
EB304162
ADJUSTING THE REAR SHOCK
ABSORBER ASSEMBLY
WARNINGWARNING
Securely support the motorcycle so that
there is no danger of it falling over.
Spring preload
ACHTUNG:CAUTION:
Never go beyond the maximum or mini-
mum adjustment positions.
1. Adjust:
• spring preload
NOTE:
Adjust the spring preload with the spe-
cial wrench and extension bar included
in the owner’s tool kit.
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. Turn the adjusting knob 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 a
(turns in)Spring preload is
increased (suspension is
harder).
Direction b
(turns out)Spring preload is
decreased (suspension is
softer).
Adjusting positions
Minimum: 0 turns in*
Standard: 6 turns in *
Maximum: 20 turns in *
* from the fully turned-out position
1
1
a a
b b
ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY

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

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.