tow YAMAHA YZF-R7 1999 Owners Manual

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 - 10
INSTRUMENT AND CONTROL FUNCTIONS
1 1

1. Shift pedal
EAU00157
Shift pedal
This motorcycle is equipped with a con-
stant-mesh 6-speed transmission.
The shift pedal is located on the left
side of the engine and is used in com-
bination with the clutch when shifting.
1. Lever position adjusting dial
2. Arrow mark
a. Lever distance
EAU00161
Front brake lever
The front brake lever is located on the
right handlebar and is equipped with a
brake lever adjusting dial.
To activate the front brake, pull the le-
ver toward the handlebar.
To adjust the front brake lever position,
turn the brake lever adjusting dial while
pulling the lever forward. Make sure the
setting on the brake lever adjusting dial
is aligned with the arrow mark.
1 1
1. Rear brake pedalEAU00162
Rear brake pedal
The rear brake pedal is on the right
side of the motorcycle. Press down on
the brake pedal to apply the rear brake.
1. OpenEAU00172
Fuel tank cap
To open
Insert the key and turn it 1/4 turn clock-
wise. The lock will be released and the
cap can be opened.
To close
Push the tank cap into position with the
key inserted. To remove the key, turn it
counterclockwise to the original posi-
tion.
1 1NOTE:
This tank cap cannot be closed unless
the key is in the lock. The key cannot
be removed if the cap is not locked
properly.
EW000023
WARNING
Be sure the cap is properly installed
and locked in place before riding the
motorcycle.
1. Filler tube
2. Fuel level
EAU01183
Fuel
Make sure there is sufficient fuel in the
tank. Fill the fuel tank to the bottom of
the filler tube as shown in the illustra-
tion.
EW000130
WARNING
Do not overfill the fuel tank. Avoid
spilling fuel on the hot engine. Do
not fill the fuel tank above the bot-
tom of the filler tube or it may over-
flow when the fuel heats up later and
expands.

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 - 19
TROUBLESHOOTING CHART
5. Engine overheatingEW000070
WARNING
Do not remove the radiator cap when the engine and radiator are hot. Scalding hot fluid and steam may be blown out
under pressure, which could cause serious injury. Open the radiator cap as follows. Wait until the engine has
cooled. Remove the radiator cap stopper by removing the screw. Place a thick rag like a towel over the radiator cap
and slowly rotate the cap counterclockwise to the detent. This procedure allows any residual pressure to escape.
When the hissing sound has stopped, press down on the cap while turning counterclockwise and remove it.
NOTE:
If it is difficult to get the recommended coolant, tap water can be temporarily used, provided that it is changed to the recom-
mended coolant as soon as possible.
Wait until the
engine has cooled.Check the coolant level in the
reservoir tank and/or radiator.
Level is OK.
Level is low, check the
cooling system for leakage.
No
leakage.
Leakage.Ask a Yamaha dealer to inspect
and repair the cooling system.
Add coolant. (See NOTE.)
Restart the engine. If the engine overheats again, ask a
Yamaha dealer to inspect and repair the cooling system.

3 - 33
CHK
ADJ
CHANGING THE COOLANT
EB303240
CHANGING THE COOLANT
1. Remove:
• bottom cowling
• front cowling
Refer to “COWLINGS”.
2. Remove:
• coolant reservoir bolts 1
• coolant reservoir cap 2
NOTE:
When draining the coolant from the
coolant reservoir, be sure to tilt the res-
ervoir so that coolant cannot flow
through the coolant reservoir breather
hose 3.
3. Drain:
• coolant
(from the coolant reservoir)
4. Install:
• coolant reservoir bolts
2
2

1

1

5. Remove:
• radiator cap 1
WARNINGWARNING
A hot radiator is under pressure. There-
fore, do not remove the radiator cap
when the engine is hot. Scalding hot
fluid and steam may be blown out,
which could cause serious injury. When
the engine has cooled, open the radiator
cap as follows:
Place a thick rag or a towel over the
radiator cap and slowly turn the radia-
tor cap counterclockwise toward the
detent to allow any residual pressure to
escape. When the hissing sound has
stopped, turn the radiator cap counter-
clockwise while pressing down on it
and then remove it.
1
1

6. Remove:
• coolant drain bolt 1
(along with the copper washer)
7. Drain:
• coolant

4 - 55
ENGOIL PAN AND OIL PUMP
2. Check:
• oil pump operation
Refer to “CHECKING THE OIL PUMP”.
EB411710
INSTALLING THE OIL PUMP
1. Install:
• oil pump 1
NOTE:
Install the oil/water pump assembly
drive chain onto the oil/water pump
assembly driven sprocket.
T R..12 Nm (1.2 m · kg, 8.7 ft · lb)
EB411720
INSTALLING THE OIL STRAINER
1. Install:
• oil strainer 1
NOTE:
The arrow a on the oil strainer housing
must point towards the front of the
engine.
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)
EB411730
INSTALLING THE OIL PAN
1. Install:
• dowel pins
• oil pan gasket
• oil pan 1
• oil level switch 2
• engine oil drain bolt 3
WARNINGWARNING
Always use new copper washers.
NOTE:
• Tighten the oil pan bolts in stages and
in a crisscross pattern.
• Lubricate the oil level switch O-ring
with lithium soap base grease.
New
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)
T R..43 Nm (4.3 m · kg, 31 ft · lb)

4 - 69
ENGCONNECTING RODS AND PISTONS
c. Put a piece of Plastigaugeâ 1 on the
crankshaft pin.
d. Assemble the connecting rod halves.
NOTE:
• Do not move the connecting rod or
crankshaft until the clearance mea-
surement has been completed.
• Lubricate the bolt threads and nut
seats with MOLYKOTE
® G-n paste.
• Make sure that the “Y” mark c on the
connecting rod faces towards the left
side of the crankshaft.
• Make sure that the characters d on
both the connecting rod and connect-
ing rod cap are aligned.
e. Tighten the connecting rod nuts.
Refer to “INSTALLING THE PISTONS
AND CONNECTING RODS”.
f. Remove the connecting rod and big
end bearings.
Refer to “REMOVING THE CONNECT-
ING RODS AND PISTONS”.
g. Measure the compressed Plasti-
gauge
â width e on the crankshaft
pin.
If the crankshaft pin-to-big end bear-
ing clearance is out of specification,
select replacement big end 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

4 - 72
ENGCONNECTING RODS AND PISTONS
NOTE:
Apply only a thin even layer of
MOLYKOTE‚ “G-n” paste, otherwise the
correct tightening torque cannot be
achieved.
6. Lubricate:
• crankshaft pins
• big end bearings
• connecting rod big end inner surface
(with the recommended lubricant)
Recommended lubricant
Engine oil
7. Install:
• big end bearings
• connecting rod assembly
(into the cylinder and onto the crank-
shaft pin)
• connecting rod cap
(onto the connecting rod)
NOTE:
• Align the projections on the big end
bearings with the notches in the con-
necting rods and connecting rod caps.
• Be sure to reinstall each big end bear-
ing in its original place.
• While compressing the piston rings
with piston ring compressor 1, install
the connecting rod assembly into the
cylinder with the other hand.
• Make sure that the “Y” marks a on the
connecting rods face towards the left
side of the crankshaft.
• Make sure that the characters b on
both the connecting rod and connect-
ing rod cap are aligned.
8. Align:
• bolt heads
(with the connecting rods)
Piston ring compressor:
90890-05158
1

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 - 86
CHAS
EB707700
INSTALLING THE SWINGARM
1. Lubricate:
• bearings
• spacers
• dust covers
• pivot shaft
2. Install:
• spacers
• swingarm
• pivot shaft bosses
• pivot shaft
• washer
• pivot shaft nut
3. Install:
• drive chain pullers
NOTE:
Install the drive chain pullers onto the
swingarm so that the sides stamped
“IN” face toward the inside (i.e., the rear
wheel).
4. Install:
• rear shock absorber assembly
• rear wheel
Refer to “REAR SHOCK ABSORBER
ASSEMBLY” and “REAR WHEEL”.
5. Adjust:
• drive chain slack
Refer to “ADJUSTING THE DRIVE
CHAIN SLACK” in chapter 3.
Recommended lubricant
Molybdenum disulfide grease
Drive chain slack
40 ~ 50 mm (1.57 ~ 1.97 in)
T R..125 Nm (12.5 m · kg, 90 ft · lb)
SWINGARM AND DRIVE CHAIN