1999 YAMAHA YZF-R7 ABS

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 - 2
DESCRIPTION
DESCRIPTION
Left view
Right view
1. Front fork compression damping force adjusting screw
2. Front fork rebound damping force adjusting screw
3. Front fork spring preload adjusting bolt
4. Air filter
5. Starter (choke) “ “
6. Shift pedal
7. Rear shock absorber spring preload adjusting ring
8. Rear shock absorber compression damping force adjusting screw
9. Rear shock absorber rebound damping force adjusting screw
10. Fuses
11. Rear brake resorvoir
12. Rear brake pedal
13. Radiator cap and coolant reservoir tank cap
14. Engine oil filter
14
56
78
9
2,3
10
11
1213 14

1

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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.

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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

CHASSIS SPECIFICATIONSSPEC
2 - 14
Steering
Steering bearing type Angular ball bearings ----
Rear suspension
Suspension type Swingarm (link suspension) ----
Rear shock absorber assembly
typeCoil spring/gas-oil damper ----
Rear shock absorber assembly
travel63 mm (2.48 in) ----
Spring
Free length 160 mm (6.30 in) ----
Installed length 146 mm (5.75 in) ----
Spring rate (K1) 95 N/mm (9.69 kgf/mm, 543 lb/in) ----
Spring stroke (K1) 0 ~ 63 mm (0 ~ 2.48 in) ----
Optional spring available No ----
Standard spring preload gas/air
pressure 1,200 kPa (12 kgf/cm
2, 171 psi) ----
Spring preload adjusting positions
Minimum 0 [11 mm (0.43 in)] ----
Standard 6 [14 mm (0.55 in)] ----
Maximum 20 [21 mm (0.84 in)] ----
Rebound damping adjusting posi-
tions
Minimum* 50 ----
Standard* 10 ----
Maximum* 0 ----
Compression damping adjusting
positions
Minimum* 25 ----
Standard* 10 ----
Maximum* 0 ----
* from the fully turned-in position
Swingarm
Free play (at the end of the swing-
arm)
Radial ---- 1 mm
(0.04 in)
Axial ---- 1 mm
(0.04 in)
Drive chain
Model (manufacturer) 50ZVM (DAIDO) ----
Link quantity 118 ----
Drive chain slack 40 ~ 50 mm (1.57 ~ 1.97 in) ----
Maximum ten-link section 150.1 mm (5.91 in) ----Item Standard Limit

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SPEC
CHASSIS TIGHTENING TORQUES
HINWEIS:NOTE:
1.First, tighten the ring nut to approximately 18 Nm (1.8 m • kg, 13 ft • lb) with a torque
wrench, then loosen the ring nut completely.
2.Retighten the ring nut to specification.Item Thread sizeTightening torque
Remarks
Nm m·kgf ft·lb
Upper bracket pinch bolts M8 26 2.6 19
Steering stem nut M28 115 11.5 85
Handlebar pinch bolts M6 13 1.3 9.4
Lower ring nut M30 9 0.9 6.5 See NOTE.
Lower bracket pinch bolts M6 11 1.1 8.0
Front brake hose union bolts M10 30 3.0 22
Front brake master cylinder M6 13 1.3 9.4
Engine mounting
Spacer bolts M16 18 1.8 13
Left front mounting bolts M10 40 4.0 29
Right front mounting bolts M10 40 4.0 29
Rear mounting bolts M10 55 5.5 40
Pinch bolts M8 17 1.7 12
Exhaust pipe bracket M8 24 2.4 17
Pivot shaft nut M18 125 12.5 90
Connecting arms M10 40 4.0 29
Relay arm and connecting arms M10 40 4.0 29
Relay arm M10 40 4.0 29
Rear shock absorber and relay arm M10 40 4.0 29
Rear shock absorber assembly M10 40 4.0 29
Fuel pump and fuel tank M5 4 0.4 2.9
Coolant reservoir and radiator M6 5 0.5 3.6
Rider footrest bracket M8 28 2.8 20
Rear master cylinder M8 23 2.3 17
Rear brake hose union bolts M10 30 3.0 22
Sidestand bracket M8 26 2.6 19
Front wheel axle M20 79 7.9 57
Rear wheel axle M24 150 15.0 110
Rear wheel axle nut M24 45 4.5 32
Front brake caliper and front fork M10 40 4.0 29
Rear brake caliper and bracket M10 40 4.0 29
Brake disc and wheel M6 18 1.8 13
Rear wheel sprocket and rear wheel
drive hubM10 69 6.9 50
Brake caliper and bleed screw M8 6 0.6 4.3
Pinch bolt (front wheel axle) M8 23 2.3 17
TIGHTENING TORQUES

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CHK
ADJ

PERIODIC MAINTENANCE AND LUBRICATION
INTERVALS
*
Since these items require special tools, data and technical skills, they should be serviced by a
Yamaha dealer.
NOTE:

• The air filter element needs more frequent service if you are riding in unusually wet or
dusty areas.
• Hydraulic brake system
– Replace the brake fluid or clutch fluid after disassembling the master cylinder, caliper cyl-
inder or release cylinder.
– Check the brake fluid or clutch fluid level and add fluid as required.
– Replace the master cylinder, caliper cylinder and release cylinder oil seals every two
years.
– Replace the brake hoses and clutch hose every four years, or if cracked or damaged.
15
*
Chassis fasteners
• Make sure that all nuts, bolts and screws are properly
tightened.
• Tighten if necessary.
ÖÖ
16 Sidestand
• Check operation.
• Lubricate and repair if necessary.
ÖÖ
17
*
Sidestand switch
• Check operation.
• Replace if necessary.
ÖÖÖ
18
*
Front fork
• Check operation and for oil leakage.
• Correct accordingly.
ÖÖ
19
*
Rear shock
absorber assembly
• Check operation and shock absorber for oil leakage.
• Replace shock absorber assembly if necessary.
ÖÖ
20
*
Rear suspension
relay arm and con-
necting arm pivot-
ing points
• Check operation.
• Lubricate with lithium soap base grease every 24,000
km or 24 months (whichever comes first).
ÖÖ
21
*
Electronic fuel
injection system
• Check engine idling speed, synchronization and
starter operation.
• Adjust if necessary.
ÖÖÖ
22 Engine oil
• Check oil level and vehicle for oil leakage.
• Correct if necessary.
• Change. (Warm engine before draining.)
ÖÖÖ
23Engine oil filter
cartridge
• Replace.
ÖÖ
24
*
Cooling system
• Check coolant level and vehicle for coolant leakage.
• Correct if necessary.
• Change coolant every 24,000 km 24 months (which-
ever comes first).
ÖÖ
No. ITEM CHECKS AND MAINTENANCE JOBSINITIAL
1,000 km EVERY
6,000 km or
6 months
(whichever
comes first)12,000 km or
12 months
(whichever
comes first)
3

3 - 45
CHK
ADJ
CHECKING AND ADJUSTING THE STEERING HEAD
c. Loosen the lower ring nut completely,
then tighten it to specification.
WARNINGWARNING
Do not overtighten the lower ring nut.
d. Check the steering head for looseness
or binding by turning the front fork all
the way in both directions. If any
binding is felt, remove the lower
bracket and check the upper and
lower bearings.
Refer to “STEERING HEAD” in chap-
ter 7.
e. Install the rubber washer 3.
f. Install the upper ring nut 2.
g. Finger tighten the upper ring nut 2,
then align the slots of both ring nuts.
If necessary, hold the lower ring nut
and tighten the upper ring nut until
their slots are aligned.
h. Install the lock washer 1.
NOTE:
Make sure that the lock washer tabs a
sit correctly in the ring nut slots 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
T R..
Lower ring nut (final tightening
torque)
9 Nm (0.9 m • kg, 6.5 ft • lb)
9. Install:
• steering stem nut
• upper bracket bolt
• handlebar pinch bolt
• upper bracket pinch bolt
10.Measure:
• steering head tension
(with the motorcycle still on the stand)
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
NOTE:
Make sure that all of the cables and
wires are properly routed.
a. Point the front wheel straight ahead.
b. Install a plastic locking tie 1 loosely
around the end of the handlebar as
shown.
c. Hook a spring gauge 2 onto the plas-
tic locking tie.
T R..115 Nm (11.5 m · kg, 85 ft · lb)
T R..13 Nm (1.3 m · kg, 9.4 ft · lb)
T R..13 Nm (1.3 m · kg, 9.4 ft · lb)
T R..26 Nm (2.6 m · kg, 16 ft · lb)