ESP YAMAHA YZF-R7 1999 Owners Manual

1 - 13
OPERATION AND IMPORTANT RIDING POINTS
1. Turn the main switch to “ON” and
the engine stop switch to “ ”.
ECA00005
CAUTION:
The warning light and fuel indicator
light should come on for a few sec-
onds and then go off. If an indicator
light does not go off, refer to the cor-
responding indicator light circuit
check in the “INSTRUMENT AND
CONTROL FUNCTIONS” section.
2. Shift the transmission into neutral.
NOTE:
When the transmission is in neutral, the
neutral indicator light should be on. If
the light does not come on, ask a
Yamaha dealer to inspect it.
3. Turn on the starter (choke) and
completely close the throttle grip.
4. Start the engine by pushing the
start switch.
NOTE:
If the engine fails to start, release the
start switch, wait a few seconds, then
try again. Each attempt should be as
short as possible to preserve the bat-
tery. Do not crank the engine more
than 10 seconds on any one attempt.5. After starting the engine, move
the starter (choke) to the halfway
position.
NOTE:
For maximum engine life, never accel-
erate hard with a cold engine!
6. After the engine is warm, turn off
the starter (choke) completely.
NOTE:
The engine is warm when it responds
normally to the throttle with the starter
(choke) turned off.
EAU01258
Starting a warm engine
The starter (choke) is not required
when the engine is warm.
EC000046
CAUTION:
See the “Engine break-in” section
prior to operating the motorcycle for
the first time.
1 16
65
5
4 4
3 3
N N2 2
1 1
1. Shift pedal
N. Neutral
EAU00423
Shifting
The transmission lets you control the
amount of power you have available at
a given speed for starting, accelerating,
climbing hills, etc. The use of the shift
pedal is shown in the illustration.
To shift into neutral, depress the shift
pedal repeatedly until it reaches the
end of its travel, then raise the pedal
slightly.
EC000048
CAUTION:
lDo not coast for long periods
with the engine off, and do not
tow the motorcycle a long dis-
tance. Even with gears in neu-
tral, the transmission is only
properly lubricated when the
engine is running. Inadequate
lubrication may damage the
transmission.
lAlways use the clutch when
changing gears. The engine,
transmission, and driveline are
not designed to withstand the
shock of forced shifting and
can be damaged by shifting
without using the clutch.

1 - 15
MOTORCYCLE CARE AND STORAGE
Care
The exposure of its technology makes
a motorcycle charming but also vulner-
able. Although high-quality compo-
nents are used, they are not all rust-
resistant. While a rusty exhaust pipe
may remain unnoticed on a car, it does
look unattractive on a motorcycle. Fre-
quent and proper care, however, will
keep your motorcycle looking good, ex-
tend its life and maintain its perfor-
mance. Moreover, the warranty states
that the vehicle must be properly taken
care of. For all these reasons, it is rec-
ommended that you observe the fol-
lowing cleaning and storing
precautions.Before cleaning
1. Cover up the muffler outlet with a
plastic bag.
2. Make sure that all caps and cov-
ers as well as all electrical cou-
plers and connectors, including
the spark plug caps, are tightly in-
stalled.
3. Remove extremely stubborn dirt,
like oil burnt onto the crankcase,
with a degreasing agent and a
brush, but never apply such prod-
ucts onto seals, gaskets, sprock-
ets, the drive chain and wheel
axles. Always rinse the dirt and
degreaser off with water.Cleaning
After normal useRemove dirt with warm water, a neutral
detergent and a soft clean sponge,
then rinse with plenty of clean water.
Use a tooth or bottle brush for hard-to-
reach parts. Tougher dirt and insects
will come off more easily if the area is
covered with a wet cloth for a few min-
utes before cleaning.
MOTORCYCLE CARE AND STORAGE
ECA00010
CAUTION:
lAvoid using strong acidic
wheel cleaners, especially on
spoked wheels. If you do use
such products for hard-to-re-
move dirt, do not leave it on any
longer than instructed, then
thoroughly rinse it off with wa-
ter, immediately dry the area
and apply a corrosion protec-
tion spray.
lImproper cleaning can damage
windshields, cowlings, panels
and other plastic parts. Use
only a soft, clean cloth or
sponge with mild detergent and
water to clean plastic.
lDo not use any harsh chemical
products on plastic parts. Be
sure to avoid using cloths or
sponges which have been in
contact with strong or abrasive
cleaning products, solvent or
thinner, fuel (gasoline), rust re-
movers or inhibitors, brake flu-
id, antifreeze or electrolyte.
lDo not use high-pressure
washers or steam-jet cleaners
since they cause water seep-
age and deterioration in the fol-
lowing areas: seals (of wheel
bearings, swingarm bearings,
forks and brakes), electric com-
ponents (couplers, connectors,
instruments, switches and
lights), breather hoses and
vents.
lFor motorcycles equipped with
a windshield: Do not use strong
cleaners or hard sponges as
they will cause dulling or
scratching. Some cleaning
compounds for plastic may
leave scratches on the wind-
shield. Test the product on a
small hidden part of the wind-
shield to make sure they do not
leave any marks. If the wind-
shield is scratched, use a quali-
ty plastic polishing compound
after washing.
lDo not rub the frame, swingarm
and other similar matte metal
parts with a cloth (neither one
dampened with solvents or
gasoline nor a dry one), as this
may deteriorate their finish.
Wash off dirt with water only.
For hard-to-remove dirt, add a
mild detergent and rub only
lightly.
After riding in the rain, near the sea or
on salt-sprayed roads
Since sea salt or salt sprayed on the
roads in the winter are extremely corro-
sive in combination with water, carry
out the following steps after each ride
in the rain, near the sea or on salt-
sprayed roads. (Salt sprayed in the
winter may remain on the roads well
into spring.)

1 - 16
MOTORCYCLE CARE AND STORAGE
1. Clean your motorcycle with cold
water and soap after the engine
has cooled down.
ECA00012
CAUTION:
Do not use warm water since it in-
creases the corrosive action of the
salt.
2. Be sure to apply a corrosion pro-
tection spray on all (even chrome-
and nickel-plated) metal surfaces
to prevent corrosion.After cleaning
1. Dry the motorcycle with a cham-
ois or an absorbing cloth.
2. Immediately dry the drive chain
and lubricate it to prevent it from
rusting.
3. Use a chrome polish to shine
chrome, aluminum and stainless-
steel parts, including the exhaust
system. (Even the thermally in-
duced discoloring of stainless-
steel exhaust systems can be re-
moved through polishing.)
4. To prevent corrosion, it is recom-
mended to apply a corrosion pro-
tection spray on all (even chrome-
and nickel-plated) metal surfaces.
5. Use spray oil as a universal clean-
er to remove any remaining dirt.
6. Touch up minor paint damage
caused by stones, etc.
7. Wax all painted surfaces.
CAUTION:
Do not wax the frame, swingarm and
other similar matte metal parts, as
this may deteriorate their finish.
8. Let the motorcycle dry completely
before storing it or covering it.
EWA00001
WARNING
Make sure that there is no oil or wax
on the brakes and tires. If necessary,
clean the brake discs and linings
with a regular brake disc cleaner or
acetone, and wash the tires with
warm water and mild soap. Then,
carefully test the motorcycle for its
braking performance and cornering
behavior.
ECA00013
CAUTION:
lApply spray oil and wax spar-
ingly and wipe off any excess.
lNever apply oil or wax on rub-
ber and plastic parts, but treat
them with a suitable care prod-
uct.
lAvoid using abrasive polishing
compounds as they wear away
the paint.
NOTE:
Consult a Yamaha dealer for advice on
what products to use.
Storage
Short-term
Always store your motorcycle in a cool,
dry place and, if necessary, protect it
against dust with a porous cover.
ECA00014
CAUTION:
lStoring the motorcycle in a
poorly ventilated room or cov-
ering it with a tarp while it is still
wet will allow water and humid-
ity to seep in and cause rust.
lTo prevent corrosion, avoid
damp cellars, stables (because
of the presence of ammonia)
and areas where strong chemi-
cals are stored.Long-term
Long term storage (60 days or more) of
your motorcycle will require some pre-
ventive procedures to guard against
deterioration. After throughly cleaning
the motorcycle, prepare for storage as
follows:
1. Drain the fuel tank.
2. Remove the empty fuel tank, pour
a cup of engine oil in the tank,
shake the tank to coat the inner
surfaces thoroughly and drain off
the excess oil. Reinstall the tank.
3. Remove the spark plug, pour
about one tablespoon of engine
oil in the spark plug hole and rein-
stall the spark plug. Turn the en-
gine over several times (ground
spark plug lead wires) to coat the
cylinder walls with oil.

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.

4 - 70
ENGCONNECTING RODS AND PISTONS
2. Select:
• big end bearings (“P
1”~ “P4”)
NOTE:
• The numbers stamped into the crank-
shaft web and the numbers on the
connecting rods are used to determine
the replacement big end bearing sizes.
•“P
1”~“P4” refer to the bearings shown
in the crankshaft illustration.
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
For example, if the connecting rod
“P
1” and the crankshaft web “P1” num-
bers are “9” and “3” respectively, then
the bearing size for “P
1” is:
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
“P1” (connecting rod) – “P1” (crank-
shaft) =
9 – 3 = 6
BIG END BEARING COLOR CODE
2 blue
3
black
4
5
brown
6
7
green
8
9 yellow
EB404704
INSTALLING THE PISTONS AND
CONNECTING RODS
The following procedure applies to all of
the pistons and cylinders.
1. Install:
• top ring
• 2nd ring
• oil ring
NOTE:
Be sure to install the piston rings so that
the manufacturer’s marks or numbers
face up.

4 - 71
ENGCONNECTING RODS AND PISTONS
2. Install:
• piston 1
(onto the respective connecting rod 2)
• piston pin 3
• piston pin clip 4
NOTE:
• Apply engine oil onto the piston pin.
• Make sure that the “Y” mark a on the
connecting rod faces left when the
arrow mark b on the piston is pointing
up. Refer to the illustration.
• Reinstall each piston into its original
cylinder (numbering order starting
from the left: #1 to #4).
Piston head
New
3. Offset:
• piston ring end gaps
aTop ring
bLower oil ring rail
cUpper oil ring rail
d2nd ring
Intake side
4. Lubricate:
• piston
• piston rings
• cylinder
(with the recommended lubricant)
5. Lubricate:
• bolt threads
• nut seats
(with the recommended lubricant)
ACHTUNG:CAUTION:
MOLYKOTEâ “G-n” paste is a special
grease, which should not be applied to
any part other than those specified.
Recommended lubricant
Engine oil
Recommended lubricant
MOLYKOTE® G-n paste

4 - 77
ENGCRANKSHAFT
g. Remove the lower crankcase and the
crankshaft journal lower bearings.
h. Measure the compressed Plasti-
gauge
Ò width c on each crankshaft
journal.
If the clearance is out of specification,
select replacement crankshaft jour-
nal bearings.
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
2. Select:
• crankshaft journal bearings (J
1 ~ J5)
NOTE:
• The numbers stamped into the crank-
shaft web and the numbers stamped
into the lower crankcase are used to
determine the replacement crankshaft
journal bearing sizes.
•“J
1” ~ “J5” refer to the bearings shown
in the crankshaft illustration.
• If “J
1” ~ “J5” are the same, use the
same size for all of the bearings.
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
For example, if the crankcase “J1” and
crankshaft web “J
1” numbers are “8”
and “3” respectively, then the bearing
size for “J
1” is:
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
Bearing size for J1:
“J
1” (crankcase) – “J1” (crankshaft
web) =
8 – 3 = 5
CRANKSHAFT JOURNAL BEARING
COLOR CODE
1
blue
2
3
black
4
5
brown
6
7
green
8
9
yellow
10
11 violet

4 - 87
ENGTRANSMISSION
4. Check:
• transmission gear engagement
(each pinion gear to its respective
wheel gear)
Incorrect ® Reassemble the transmis-
sion axle assemblies.
5. Check:
• transmission gear movement
Rough movement ® Replace the
defective part(-s).
6. Check:
• circlips
Bends/damage/looseness ® Replace.
INSTALLING THE TRANSMISSION
1. Install:
• main axle assembly
• shift fork “C”
• shift drum assembly
• shift fork “R”
• shift fork “L”
• springs
• shift fork guide bars
• drive axle assembly
NOTE:
• Install the shift forks so that the
embossed marks “C”, “R”, and “L” are
facing toward the right side of the
engine.
• Carefully position the shift forks so
that they are installed correctly into the
transmission gears.
• Install shift fork “C” into the groove in
the 3rd and 4th pinion gear on the
main axle.
• Install shift fork “L” into the groove in
the 6th wheel gear and shift fork “R”
into the groove in the 5th wheel gear
on the drive axle.
• Make sure that the drive axle bearing
circlip is inserted into the grooves in
the upper crankcase.
2. Check:
• transmission
Rough movement ® Repair.
NOTE:
Oil each gear, shaft, and bearing thor-
oughly.

7 - 13
CHAS
REAR WHEEL, BRAKE DISC, AND REAR WHEEL
SPROCKET
3. Measure:
• radial wheel runout
• lateral wheel runout
Refer to “FRONT WHEEL”.
Over the specified limits ® Replace.
Max. radial wheel runout
1.0 mm (0.04 in)
Max. lateral wheel runout
0.5 mm (0.02 in)
EB701430
CHECKING THE REAR WHEEL DRIVE HUB
1. Check:
• rear wheel drive hub 1
Cracks/damage ® Replace.
• rear wheel drive hub dampers 2
Damage/wear ® Replace.
EB701440
CHECKING AND REPLACING THE REAR
WHEEL SPROCKET
1. Check:
• rear wheel sprocket
More than 1/4 tooth a wear ® Replace
the rear wheel sprocket.
Bent teeth ® Replace the rear wheel
sprocket.
b
Correct
1Drive chain roller
2Rear wheel sprocket
2. Replace:
• rear wheel sprocket
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. Remove the self-locking nuts and the
rear wheel sprocket.
b. Clean the rear wheel drive hub with a
clean cloth, especially the surfaces
that contact the sprocket.
c. Install the new rear wheel sprocket.
NOTE:
Tighten the self-locking nuts in stages
and in a crisscross pattern.
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
T R..
Rear wheel sprocket self-lock-
ing nut
150 Nm (15.0 m • kg, 110 ft • lb)

7 - 77
CHAS
EB706101
HANDLING THE REAR SHOCK ABSORBER
AND GAS CYLINDER
WARNINGWARNING
This rear shock absorber and gas cylin-
der contain highly compressed nitro-
gen gas. Before handling the rear shock
absorber or gas cylinder, read and make
sure you understand the following
information. The manufacturer cannot
be held responsible for property dam-
age or personal injury that may result
from improper handling of the rear
shock absorber and gas cylinder.
• Do not tamper or attempt to open the
rear shock absorber or gas cylinder.
• Do not subject the rear shock absorber
or gas cylinder to an open flame or
any other source of high heat. High
heat can cause an explosion due to
excessive gas pressure.
• Do not deform or damage the rear
shock absorber or gas cylinder in any
way. If the rear shock absorber, gas
cylinder or both are damaged, damp-
ing performance will suffer.
EB706111
DISPOSING OF A REAR SHOCK ABSORBER
AND GAS CYLINDER
Gas pressure must be released before dis-
posing of a rear shock absorber and gas cyl-
inder. To release the gas pressure, press on
the gas valve needle with a suitable tool as
shown, until all of the gas is released (the
hissing has stopped).
WARNINGWARNING
Wear eye protection to prevent eye
damage from released gas or metal
chips.
REAR SHOCK ABSORBER ASSEMBLY