light 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 - 4
INSTRUMENT AND CONTROL FUNCTIONS
INSTRUMENT AND CONTROL FUNCTIONS
EAU00029
Main switch/Steering lock
The main switch controls the ignition
and lighting systems. Its operation is
described below.
EAU00036
ON
Electrical circuits are switched on. The
engine can be started. The key cannot
be removed in this position.
EAU00038
OFF
All electrical circuits are switched off.
The key can be removed in this posi-
tion.
EAU00040
LOCK
The steering is locked in this position
and all electrical circuits are switched
off. The key can be removed in this po-
sition. To lock the steering, turn the
handlebars all the way to the left. While
pushing the key into the main switch,
turn it from “OFF” to “LOCK” and re-
move it. To release the lock, turn the
key to “OFF” while pushing.
1. Push
2. Turn
EW000016
WARNING

Never turn the key to “OFF” or
“LOCK” when the motorcycle is
moving. The electrical circuits will
be switched off which may result in
loss of control or an accident. Be
sure the motorcycle is stopped be-
fore turning the key to “OFF” or
“LOCK”.
EAU01574
(Parking)
The steering is locked in this posi-
tion, and the taillights and auxiliary
lights come on, but all other circuits
are off. The key can be removed in
this position.
To use the parking position, first
lock the steering, then turn the key
to “ ”. Do not use this position for
an extended length of time as the
battery may discharge.
1.
Neutral indicator light “ ”
2. High beam indicator light “ ”
3. Turn indicator light “ ”
4. Fuel indicator light “ ”
EAU00056
Indicator lights
EAU00061
Neutral indicator light “ ”
This indicator comes on when the
transmission is in neutral.
EAU00063
High beam indicator light “ ”
This indicator comes on when the
headlight high beam is used.
EAU00057
Turn indicator light “ ”
This indicator flashes when the turn
switch is moved to the left or right.
EAU01154
Fuel indicator light “ ”
When the fuel level drops below
approximately 4.8 L, this light will
come on. When this light comes
on, fill the tank at the first opportuni-
ty. This light circuit can be checked
by the procedure on page 1-7.
If there is a shortcircuit or disconti-
nuity at the thermistor, the fuel indi-
cator light will flash 8 times and
then stay off for 3 seconds repeat-
edly.

1 - 5
INSTRUMENT AND CONTROL FUNCTIONS
4 681012
14
x1000r/min
0
1 12
3 3
4

1. Warning light
2. Oil level symbol “ ”
3. Coolant temperature symbol “ ”
4. Engine trouble symbol “ ”
EAU01564
Warning light
This indicator light has three functions.
l
The light will come on and symbol
“ ” will flash if the engine oil
level is low.
If this symbol flashes, stop the en-
gine immediately and fill it with oil
to the specified level.
l
The light will come on and symbol
“ ” will flash if trouble occurs in
a monitoring circuit. In such a
case, take the motorcycle to a
Yamaha dealer to have the self-
diagnostic systems checked.
l
The light will come on and symbol
“ ” will flash if the coolant tem-
perature is too high. The following
chart shows the conditions of the
indicator light, symbol and tem-
perature display in accordance to
coolant temperature.
The light circuit can be checked by the
procedure on page 1-6.
EC000118
CAUTION:

l
Do not run the motorcycle until
you know it has sufficient en-
gine oil.
l
Do not run the motorcycle if the
engine is overheated.
NOTE:

Even if the oil is filled to the specified
level, the indicator light may flicker
when riding on a slope or during sud-
den acceleration or deceleration, but
this is normal.
CB-74ECB-74E
Coolant
temperatureDisplay Conditions What to do
~ 39 ˚CSymbol is on and “LO” is
displayed.OK. Go ahead with riding.
40 ˚C ~ 120 ˚CSymbol is on and temper-
ature is displayed.OK. Go ahead with riding.
121 ˚C ~ 139 ˚CSymbol and temperature
flash.
Warning light comes on.Stop the motorcycle and al-
low it to idle until coolant tem-
perature goes down.
If the temperature does not
go down, stop the engine.
140 ˚C ~ Symbol and message
“HI” flash.
Warning light comes on.Stop the engine and allow it
to cool. Seen page 1-19 if the
engine overheats.
—Symbol and message
“Err” flash.
Warning light comes on.Ask a Yamaha dealer to in-
spect the motorcycle.
C
C
C
C
C

1 - 6
INSTRUMENT AND CONTROL FUNCTIONS
Warning light circuit check
CB-75ECB-75E
Warning light comes on. After a few seconds:Warning light does not come on.
Have a Yamaha
dealer inspect the
electrical circuit.
Turn the main switch to “ON”.
Have a Yamaha dealer inspect
the electrical circuit.
If symbol “ ” is on, check the
engine temperature. (See page 1-5.)
Warning light goes off.
No symbol is on.Symbol “ ”,
“ ” “ ” is on.
OK. Go ahead
with riding.
Warning light does not go off.
If symbol “ ”
is on, inspect the
oil level.
Oil level is OK.Oil level is low.
Have a Yamaha dealer
inspect the electrical
circuit.Supply
recommended
engine oil.
If the engine is hot,
allow it to cool and see
“Engine overheating”
in the troubleshooting
chart on page 1-19 for
instructions.If the engine
temperature is
normal, have a
Yamaha dealer
inspect the
electrical circuit.
If symbol “ ” is on.
Have a Yamaha dealer
inspect the self-
diagnostic systems.

1 - 7
INSTRUMENT AND CONTROL FUNCTIONS
EAU01295
Fuel indicator light circuit check
CB-46ECB-69E
Turn the main switch to “ON”.
Indicator does not come
on.
Have a Yamaha dealer
inspect the electric
circuit.Indicator goes off.Indicator does not go off.
Inspect the fuel level.
Indicator comes on.
After a few seconds:
OK. Go ahead with
riding.Fuel level is OK.
Have a Yamaha
dealer inspect the
electric circuit.Fuel level is low.
Supply recommended
fuel.

1. Speedometer
2. Clock, odometer
3. “SELECT” button
4. “RESET” button
EAU01601
Digital speedometer
This speedometer is equipped with:
l
an odometer
l
two trip odometers
l
a fuel reserve trip meter
l
a clock
NOTE:

For UK models only:
To change the speedometer display
from kilometers to miles, press the “SE-
LECT” button for at least two seconds.
Odometer and trip meter modes
Use the trip meters to estimate how far
you can ride on a tank of fuel.
Use the fuel reserve trip meter to see
the distance traveled from when the
fuel level dropped to the reserve level.
Selecting a mode
Push the “SELECT” button to change
between the odometer mode “ODO”
and the trip odometer modes “TRIP 1”
and “TRIP 2” in the following order:
“ODO”
®
“TRIP 1”
®
“TRIP 2”
®
“ODO”
If the fuel level indicator light comes on
the odometer display will automatically
change to the fuel reserve trip meter
mode “TRIP F” and start counting the
distance traveled from that point. Push
the “SELECT” button to change be-
tween the fuel odometer, trip odometer
and odometer modes in the following
order:
“TRIP F”
®
“TRIP 1”
®
“TRIP 2”
®
“ODO”
®
“TRIP F”Resetting a meter
To reset a trip odometer to 0.0, select it
by pushing the “SELECT” button and
push the “RESET” button for at least
one second.
To reset the fuel reserve trip meter, se-
lect it by pushing the “SELECT” button
and push the “RESET” button for at
least one second. The display will re-
turn to “TRIP 1”. If you do not reset the
fuel reserve trip meter manually, it will
automatically reset and return to “TRIP
1” after refueling and the motorcycle
has traveled 5 km (3.1 miles).
NOTE:

After the fuel reserve trip meter is reset,
the display always returns to the “TRIP
1” mode. If “TRIP 2” was being used
before the fuel reserve trip meter is re-
set, be sure to push the “SELECT” but-
ton to change back to the “TRIP 2”
mode.

1 - 9
INSTRUMENT AND CONTROL FUNCTIONS
1 1
2 2
4 4
5 53 3

1. Pass switch “PASS”
2. Lights switch
3. Dimmer switch
4. Turn signal switch
5. Horn switch “ ”
EAU00118
Handlebar switches
EAU00120
Pass switch “PASS”
Press the switch to operate the passing
light.
EAU00134
Lights switch
Turning the lights switch to “ ”,
turns on the auxiliary light, meter lights
and taillight. Turning the lights switch to
“ ”, turns the headlight on also.
EAU00121
Dimmer switch
Turn the switch to “ ” for the high
beam and to “ ” for the low beam.
EAU00127
Turn signal switch
To signal a right-hand turn, push the
switch to “ ”. To signal a left-hand
turn, push the switch to “ ”. Once
the switch is released it will return to the
center position. To cancel the signal,
push the switch in after it has returned
to the center position.
EAU00129
Horn switch “ ”
Press the switch to sound the horn.
1 1
2 2

1. Engine stop switch
2. Start switch “ ”
EAU00138
Engine stop switch
The engine stop switch is a safety de-
vice for use in an emergency such as
when the motorcycle overturns or if
trouble occurs in the throttle system.
Turn the switch to “ ” to start the en-
gine. In case of emergency, turn the
switch to “ ” to stop the engine.
EAU00143
Start switch “ ”
The starter motor cranks the engine
when pushing the start switch.
EC000005
CAUTION:

See starting instructions prior to
starting the engine.
a a1 1
2
2

1. Lever position adjusting dial
2. Arrow mark
a. Lever distance
EAU00153
Clutch lever
The clutch lever is located on the left
handlebar. It is equipped with a clutch
lever adjusting dial and a clutch switch,
which is integrated into the ignition cir-
cuit cut-off system. (Refer to the engine
starting procedures for a description of
this system.) To disengage the clutch,
pull the clutch lever toward the handle-
bar. To engage the clutch, release the
lever. The lever should be pulled rapid-
ly and released slowly for smooth
clutch operation. To adjust the distance between the
clutch lever and the handlebar grip,
turn the clutch adjusting dial while
pushing the lever forward. Make sure
the setting on the clutch lever adjusting
dial is aligned with the arrow mark.

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 - 17
MOTORCYCLE CARE AND STORAGE/
CONSUMER INFORMATION
WARNING
When using the starter motor to
crank the engine, remove the spark
plug wires, and ground them to pre-
vent sparking.
4. Remove the drive chain. Thor-
oughly clean the chain with kero-
sene and lubricate it. Reinstall the
chain or store it in a plastic bag
(tied to frame for safekeeping).
5. Lubricate all control cables.
6. Block up the frame to raise both
wheels off the ground.
7. Tie a plastic bag over the exhaust
pipe outlet to prevent moisture
from entering.
8. If strong in a humid or salt-air at-
mosphere, coat all exposed metal
surfaces with a light film of oil. Do
not apply oil to any rubber parts or
the seat cover.9. Remove the battery and charge it.
Store it in a dry place and re-
change it once a month. Do not
store the battery in an excessively
warm or cold place (less than 0°C
(30°F) or more than 30°C (90°F)).
NOTE:
Make any necessary repairs before
storing the motorcycle.
CONSUMER INFORMATION
EAU01040
Identification numbers record
Record the key identification number,
vehicle identification number and mod-
el label information in the spaces pro-
vided for assistance when ordering
spare parts from a Yamaha dealer or
for reference in case the vehicle is sto-
len.
1. KEY IDENTIFICATION
NUMBER:
2. VEHICLE IDENTIFICATION
NUMBER:
3. MODEL LABEL INFORMATION:
1. Key identification numberEAU01041
Key identification number
The key identification number is
stamped on the key tag. Record this
number in the space provided and use
it for reference when obtaining a new
key.
1. Vehicle identification numberEAU01043
Vehicle identification number
The vehicle identification number is
stamped into the steering head pipe.
Record this number in the space pro-
vided.
NOTE:
The vehicle identification number is
used to identify your motorcycle and
may be used to register your motorcy-
cle with the licensing authority in your
state.

1 - 21
IMPORTANT INFORMATION
USING A DYNAMOMETER
The YZF-R7 has a carbon muffler that may
change color when exposed to high tem-
peratures. Therefore, when using a dyna-
mometer always use a fan to cool the
muffler.
EB102030
LOCK WASHERS/PLATES AND COTTER
PINS
After removal, replace all lock washers/
plates
1
and cotter pins. After the bolt or
nut has been tightened to specification,
bend the lock washer tabs and the cotter
pin ends along a flat of the bolt or nut.
EB102040
BEARINGS AND OIL SEALS
1. Install bearings and oil seals so that the
manufacturer’s marks or numbers are
visible. When installing oil seals, lubri-
cate the oil seal lips with a light coat of
lithium soap base grease. Oil bearings
liberally when installing, if appropriate.
1
Oil seal
ACHTUNG:CAUTION:

Do not spin the bearing with compressed
air because this will damage the bearing
surfaces.
1
Bearing
EB102050
CIRCLIPS
Before reassembly, check all circlips care-
fully and replace damaged or distorted cir-
clips. Always replace piston pin clips after
one use. When installing a circlip
1
, make
sure that the sharp-edged corner
2
is posi-
tioned opposite the thrust
3
that the circlip
receives.
4
Shaft