brakes YAMAHA YZF-R7 1999 Owners Manual

CHAPTER 6
ELECTRONIC FUEL
INJECTION
ELECTRONIC FUEL INJECTION ............... 6-1
CHAPTER 7
CHASSIS
FRONT WHEEL AND BRAKE DISCS ........ 7-1
REAR WHEEL, BRAKE DISC, AND
REAR WHEEL SPROCKET ........................ 7-9
FRONT AND REAR BRAKES .................. 7-15
HYDRAULIC CLUTCH ............................. 7-43
FRONT FORK .......................................... 7-55
HANDLEBARS ......................................... 7-67
STEERING HEAD .................................... 7-72
REAR SHOCK ABSORBER
ASSEMBLY ............................................. 7-76
SWINGARM AND DRIVE CHAIN ........... 7-80
CHAPTER 8
ELECTRICAL
ELECTRICAL COMPONENTS ................... 8-1
SWITCHES ................................................ 8-2
CHECKING THE SWITCHES ..................... 8-3
CHECKING THE BULBS AND
BULB SOCKETS ........................................ 8-4
IGNITION SYSTEM ................................... 8-7
ELECTRIC STARTING SYSTEM ............. 8-12
CHARGING SYSTEM .............................. 8-16
LIGHTING SYSTEM ................................ 8-19
SIGNALING SYSTEM ............................. 8-21
COOLING SYSTEM ................................. 8-24
ELECTRONIC FUEL INJECTION
SYSTEM .................................................. 8-28
ELECTRICAL CONTROL SYSTEM ......... 8-30

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.

CHASSIS SPECIFICATIONS
SPEC

2 - 12
Rear tire
Tire type Tubeless ----
Size 180/55 ZR17 73W ----
Model (manufacturer) MTR08 (PIRELLI) ----
Tire pressure (cold)
0 ~ 90 kg (0 ~ 198 lb) 250 kPa (2.5 kg/cm
2

, 3.6 psi) ----
90 kg (198 lb) ~ Maximum load* 290 kPa (2.9 kg/cm
2

, 4.1 psi) ----
High-speed riding 250 kPa (2.5 kg/cm
2

, 3.6 psi) ----
* Load is the total weight of the rider
and accessories.
Minimum tire tread depth ---- 1.6 mm
(0.06 in)
Front brakes
Brake type Dual-disc brake ----
Operation Right-hand operation ----
Recommended fluid DOT 4 ----
Brake discs
Diameter ´ thickness 320 ´ 5 mm (12.6 ´ 0.20 in) ----
Minimum thickness ---- 4.5 mm
(0.18 in)
Maximum deflection ---- 0.1 mm
(0.004 in)
Brake pad lining thickness 5.5 mm (0.22 in) 0.5 mm
(0.02 in)
Master cylinder inside diameter 14 mm (0.55 in) ----
Caliper cylinder inside diameter 30.2 mm (1.19 in) and 27 mm (1.06 in) ----
Rear brake
Brake type Single-disc brake ----
Operation Right-foot operation ----
Brake pedal position (from the top
of the brake pedal to the center of
the rider footrest bracket bolt)31~ 36 mm (1.22 ~ 1.42 in) ----
Recommended fluid DOT 4 ----
Brake discs
Diameter ´ thickness 245 ´ 5 mm (9.65 ´ 0.20 in) ----
Minimum thickness ---- 4.5 mm
(0.18 in)
Maximum deflection ---- 0.1 mm
(0.004 in)
Brake pad lining thickness 5.5 mm (0.22 in) 0.5 mm
(0.02 in)
Master cylinder inside diameter 12.7 mm (0.5 in) ----
Caliper cylinder inside diameter 38.2 mm (1.50 in) ----Item Standard Limit

3 - 38
CHK
ADJCHECKING THE BRAKE PADS/
ADJUSTING THE REAR BRAKE LIGHT SWITCH
EB304032
CHECKING THE BRAKE PADS
The following procedure applies to all of
the brake pads.
1. Operate the brake.
2. Check:
• front brake pad
• rear brake pad
Brake pad wear limit a
Wear limit reached ® Replace the
brake pads as a set.
Refer to “FRONT AND REAR BRAKES”
in chapter 7.
Front brake
õRear brake
Brake pad wear limit
0.5 mm (0.02 in)

õ
EB304050
ADJUSTING THE REAR BRAKE LIGHT
SWITCH
NOTE:
• The rear brake light switch is operated
by movement of the brake pedal.
• The rear brake light switch is properly
adjusted when the brake light comes
on just before the braking effect starts.
1. Check:
• rear brake light operation timing
Incorrect ® Adjust.
2. Adjust:
• rear brake light operation timing
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. Hold the main body 1 of the rear
brake light switch so that it does not
rotate and turn the adjusting nut 2 in
direction a or b until the rear brake
light comes on at the proper time.
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 aBrake light comes on
sooner.
Direction bBrake light comes on
later.

3 - 39
CHK
ADJCHECKING THE BRAKE HOSES/
BLEEDING THE HYDRAULIC BRAKE SYSTEM
EB304062
CHECKING THE BRAKE HOSES
The following procedure applies to all of
the brake hoses and brake hose clamps.
1. Check:
• brake hose 1
Cracks/damage/wear ® Replace.
2. Check:
• brake hose clamp
Loose ® Tighten the clamp bolt.
3. Hold the motorcycle upright and apply
the brake several times.
4. Check:
• brake hose
Brake fluid leakage ® Replace the
damaged hose.
Refer to “FRONT AND REAR BRAKES”
in chapter 7.
EB304072
BLEEDING THE HYDRAULIC BRAKE
SYSTEM
WARNINGWARNING
Bleed the hydraulic brake system when-
ever:
• the brake system was disassembled,
• a brake hose was loosened, discon-
nected or replaced,
• the brake fluid level is very low,
• brake operation is faulty.
NOTE:
• Be careful not to spill any brake fluid or
allow the brake fluid reservoir to over-
flow.
• When bleeding the hydraulic brake
system, make sure that there is always
enough brake fluid before applying the
brake. Ignoring this precaution could
allow air to enter the hydraulic brake
system, considerably lengthening the
bleeding procedure.
• If bleeding is difficult, it may be neces-
sary to let the brake fluid settle for a
few hours. Repeat the bleeding proce-
dure when the tiny bubbles in the hose
have disappeared.

7 - 15
CHASFRONT AND REAR BRAKES
EB702001
FRONT AND REAR BRAKES
Order Job/Part Q’ty Remarks
Removing the front brake padsRemove the parts in the order listed.
The following procedure applies to
both of the front brake calipers.
1 Brake pad clip 2
2 Brake pad pin 1
3 Brake pad spring 1
4 Brake pad 2
5 Brake pad shim 2
6 Bleed screw 1
For installation, reverse the removal
procedure.

7 - 16
CHASFRONT AND REAR BRAKES
EB702002
Order Job/Part Q’ty Remarks
Removing the rear brake padsRemove the parts in the order listed.
1 Brake pad clip 4
2 Brake pad pin 2
3 Brake pad spring 1
4 Brake pad 2
5 Brake pad shim 2
6 Bleed screw 2
For installation, reverse the removal
procedure.

7 - 17
CHASFRONT AND REAR BRAKES
EB702100
ACHTUNG:CAUTION:
Disc brake components rarely require
disassembly.
Therefore, always follow these preven-
tive measures:
• Never disassemble brake components
unless absolutely necessary.
• If any connection on the hydraulic
brake system is disconnected, the
entire brake system must be disas-
sembled, drained, cleaned, properly
filled, and bled after reassembly.
• Never use solvents on internal brake
components.
• Use only clean or new brake fluid for
cleaning brake components.
• Brake fluid may damage painted sur-
faces and plastic parts. Therefore,
always clean up any spilt brake fluid
immediately.
• Avoid brake fluid coming into contact
with the eyes as it can cause serious
injury.
First aid for brake fluid entering the
eyes:
• Flush with water for 15 minutes and
get immediate medical attention.
EB702112
REPLACING THE FRONT BRAKE PADS
The following procedure applies to both
brake calipers.
NOTE:
When replacing the brake pads, it is not
necessary to disconnect the brake hose
or disassemble the brake caliper.
1. Remove:
• brake hose holder 1
• brake caliper 2
1
1

2

2

7 - 18
CHASFRONT AND REAR BRAKES
2. Remove:
• brake pad clips 1
• brake pad pin 2
• brake pad spring 3
• brake pads
(along with the brake pad shims)
3. Measure:
• brake pad wear limit a
Out of specification ® Replace the
brake pads as a set.
Brake pad wear limit
0.5 mm (0.02 in)
4. Install:
• brake pad shims
(onto the brake pads)
• brake pads
• brake pad spring
NOTE:
Always install new brake pads, brake
pad shims, and a brake pad spring as a
set.
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 a clear plastic hose 1 tightly
to the bleed screw 2. Put the other
end of the hose into an open con-
tainer.
b. Loosen the bleed screw and push the
brake caliper pistons into the brake
caliper with your finger.
c. Tighten the bleed screw.
d. Install a new brake pad shim onto
each new brake pads.
e. Install new brake pads and a new
brake pad spring.
NOTE:
The arrow a on the brake pad spring
must point in the direction of disc rota-
tion.
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..
Bleed screw
6 Nm (0.6 m • kg, 4.3 ft • lb)