1999 YAMAHA YZF-R7 Owners Manual

INDEX
GENERAL
INFORMATION
1
SPECIFICATIONS
SPEC
2
PERIODIC CHECKS
AND
ADJUSTMENTS
3
OVERHAULING
THE ENGINE
ENG
4
COOLING SYSTEM
COOL
5
ELECTRONIC FUEL
INJECTION
EFI
6
CHASSIS
CHAS
7
ELECTRICAL
ELEC
8
GEN
INFO
CHK
ADJ
–+

EC0A0000
CONTENTS
CHAPTER 1
GENERAL INFORMATION
GIVE SAFETY THE RIGHT OF WAY ........ 1-1
DESCRIPTION ........................................... 1-2
INSTRUMENT AND CONTROL
FUNCTIONS .............................................. 1-4
OPERATION AND IMPORTANT
RIDING POINTS ...................................... 1-12
INCLUDED ACCESSORIES ..................... 1-14
MOTORCYCLE CARE AND
STORAGE ................................................ 1-15
CONSUMER INFORMATION ................. 1-17
TROUBLESHOOTING .............................. 1-18
IMPORTANT INFORMATION ................. 1-20
CHECKING THE CONNECTIONS ........... 1-22
SPECIAL TOOLS ..................................... 1-23
CHAPTER 2
SPECIFICATIONS
GENERAL SPECIFICATIONS .................... 2-1
ENGINE SPECIFICATIONS ....................... 2-2
CHASSIS SPECIFICATIONS ................... 2-11
ELECTRICAL SPECIFICATIONS ............. 2-15
TIGHTENING TORQUES ........................ 2-17
LUBRICATION POINTS AND
LUBRICANT TYPES ................................ 2-22
OIL FLOW CHART ................................... 2-24
COOLANT FLOW CHART ....................... 2-25
CABLE ROUTING .................................... 2-26

CHAPTER 3
PERIODIC CHECKS AND
ADJUSTMENTS
INTRODUCTION ....................................... 3-1
PERIODIC MAINTENANCE AND
LUBRICATION INTERVALS ...................... 3-1
GENERAL MAINTENANCE AND
LUBRICATION CHART .............................. 3-2
FUEL TANK AND AIR FILTER .................. 3-4
COWLINGS ............................................... 3-6
ENGINE ..................................................... 3-9
CHASSIS ................................................. 3-36
ELECTRICAL SYSTEM ............................ 3-55
CHAPTER 4
OVERHAULING THE ENGINE
ENGINE ..................................................... 4-1
CAMSHAFTS ............................................. 4-8
CYLINDER HEAD .................................... 4-18
VALVES AND VALVE SPRINGS ............ 4-21
GENERATOR ........................................... 4-32
PICKUP COIL ........................................... 4-35
CLUTCH ................................................... 4-39
SHIFT SHAFT .......................................... 4-48
OIL PAN AND OIL PUMP ....................... 4-50
CRANKCASE ........................................... 4-56
CONNECTING RODS AND
PISTONS ................................................. 4-63
CRANKSHAFT ......................................... 4-74
TRANSMISSION ..................................... 4-79
CHAPTER 5
COOLING SYSTEM
RADIATOR AND THERMOSTAT .............. 5-1
RADIATOR AND THERMOSTAT .............. 5-3
OIL COOLER .............................................. 5-9
WATER PUMP ......................................... 5-12

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 - 1
GIVE SAFETY THE RIGHT OF WAY
GENERAL INFORMATION
GIVE SAFETY THE RIGHT OF WAY
Motorcycles are fascinating vehicles, which can give you an unsurpassed feeling of power and freedom. Howev-
er, they also impose certain limits, which you must accept; even the best motorcycle does not ignore the laws of
physics.
Regular care and maintenance are essential for preserving your motorcycle’s value and operating condition.
Moreover, what is true for the motorcycle is also true for the rider: good performance depends on being in good
shape. Riding under the influence of medication, drugs and alcohol is, of course, out of the question. Motorcycle
riders – more than car drivers – must always be at their mental and physical best. Under the influence of even
small amounts of alcohol, there is a tendency to take dangerous risks.
Protective clothing is as essential for the motorcycle rider as seat belts are for car drivers and passengers. Al-
ways wear a complete motorcycle suit (whether made of leather or tear-resistant synthetic materials with protec-
tors), sturdy boots, motorcycle gloves and a properly fitting helmet. Optimum protective wear, however, should
not encourage carelessness. Though full-coverage helmets and suits, in particular, create an illusion of total safe-
ty and protection, motorcyclists will always be vulnerable. Riders who lack critical self-control run the risk of going
too fast and are apt to take chances. This is even more dangerous in wet weather. The good motorcyclist rides
safely, predictably and defensively – avoiding all dangers, including those caused by others.
Enjoy your ride!
1

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

1 - 3
DESCRIPTION
Controls/Instruments
1. Clutch lever
2. Left handlebar switches
3. Clutch reservoir
4. Digital speedometer
5. Main switch
6. Tachometer
7. Front brake reservoir
8. Right handlebar switches
9. Throttle grip
10. Front brake lever
12
3
456 7 8 910

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.