1999 YAMAHA YZF-R7 clutch

2 - 26
SPEC
CABLE ROUTING
1Front turn signal coupler
2Auxiliary light lead
3Headlight lead
4Throttle cable
5Left handlebar switch lead
6Clutch hose
7Front brake hose
8Right handlebar switch lead
9Main switch lead
CABLE ROUTING

2 - 28
SPEC
1Left handlebar switch lead
2Starter cable
3Main relay
4Speed sensor
5Throttle stop screw
6Sidestand switch lead
7Oil level switch lead
8Main switch lead
9Headlight and meter sub-wire har-
ness coupler0Horn lead
AHeadlight and meter sub-wire harness lead
BThrottle cable
CClutch hose
DWire harness (to headlight and meter sub-wire harness)
EWire harness
FFuel tank overflow hose
GWater pump breather hose
HCoolant reservoir breather hose
IAir filter case breather hose
CABLE ROUTING

2 - 29
SPEC
JFuel tank breather hose
KCDI unit
LFall detection switch
MFuse box
NRelay unit
Align the portions of the main
switch lead and left handle-
bar switch lead marked with
white tape with the radiator
bracket at the frame.õFasten the starter cable and wire harness with a plastic band.
‚Fasten the oil level switch lead, speed sensor lead, sidestand
switch lead and stator coil assembly lead with a plastic band.
ëFasten the air filter breather hose, fuel tank overflow hose, clutch
hose and fuel tank breather hose with a plastic band.
ä20 mm (0.79 in)
ìRoute the sidestand switch lead behind the water pump breather
hose.
íRoute the oil level switch lead to the outside of the water pump
breather hose guide.
CABLE ROUTING

3 - 1
CHK
ADJ

INTRODUCTION/PERIODIC MAINTENANCE AND
LUBRICATION INTERVALS
EB300000
PERIODIC CHECKS AND ADJUSTMENTS
INTRODUCTION
This chapter includes all information necessary to perform recommended checks and adjust-
ments. If followed, these preventive maintenance procedures will ensure more reliable vehi-
cle operation, a longer service life and reduce the need for costly overhaul work. This
information applies to vehicles already in service as well as to new vehicles that are being
prepared for sale. All service technicians should be familiar with this entire chapter.
PERIODIC MAINTENANCE AND LUBRICATION INTERVALS
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)
1
*
Fuel line
• Check fuel hoses for cracks or damage.
• Replace if necessary.
ÖÖ
2
*
Fuel filter
• Check condition.
• Replace if necessary.
Every 50,000 km
3 Spark plugs
• Check condition.
• Clean, regap or replace if necessary.
ÖÖÖ
4
*
Valves
• Check valve clearance.
• Adjust if necessary.
Every 42,000 km or 42 months (whichever
comes first)
5 Air filter element
• Clean or replace if necessary.
ÖÖ
6 Clutch
• Check operation and fluid leakage. (See NOTE on
page 3-2.)
• Correct if necessary.
ÖÖÖ
7
*
Front brake
• Check operation, fluid level and vehicle for fluid leak-
age. (See NOTE on page 3-2.)
• Correct accordingly.
• Replace brake pads if necessary.
ÖÖÖ
8
*
Rear brake
• Check operation, fluid level and vehicle for fluid leak-
age. (See NOTE on page 3-2.)
• Correct accordingly.
• Replace brake pads if necessary.
ÖÖÖ
9
*
Wheels
• Check balance, runout and for damage.
• Rebalance or replace if necessary.
ÖÖ
10
*
Tires
• Check tread depth and for damage.
• Replace if necessary.
• Check air pressure.
• Correct if necessary.
ÖÖ
11
*
Wheel bearings
• Check bearing for looseness or damage.
• Replace if necessary.
ÖÖ
12
*
Swingarm
• Check swingarm pivoting point for play.
• Correct if necessary.
• Lubricate with lithium soap base grease every 24,000
km or 24 months (whichever comes first).
ÖÖ
13 Drive chain
• Check chain slack.
• Adjust if necessary. Make sure that the rear wheel is
properly aligned.
• Clean and lubricate.
Every 1,000 km and after washing the
motorcycle or riding in rain.
14
*
Steering bearings
• Check bearing play and steering for roughness.
• Correct accordingly.
• Lubricate with lithium soap base grease every 24,000
km or 24 months (whichever comes first).
ÖÖ
3

3 - 2
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 - 23
CHK
ADJ
CHECKING THE ENGINE OIL LEVEL
EB303070
CHECKING THE ENGINE OIL LEVEL
1. Stand the motorcycle on a level surface.
NOTE:
• Place the motorcycle on a suitable stand.
• Make sure that the motorcycle is
upright.
2. Start the engine, let it idle for several
minutes, and then stop it.
3. Check:
• engine oil level
The engine oil level should be between
the minimum level mark a and maxi-
mum level mark b.
Below the minimum level mark ® Add
the recommended engine oil to the
proper level.
Recommended oil
Refer to the chart for the
engine oil grade which is best
suited for certain atmo-
spheric temperatures.
API standard
SE or higher grade
(Non-Friction modified)
ACHTUNG:CAUTION:
• Engine oil also lubricates the clutch
and the wrong oil types or additives
could cause clutch slippage. There-
fore, do not add any chemical addi-
tives or use engine oils with a grade of
CD c or higher and do not use oils
labeled “ENERGY CONSERVING II” d
or higher.
• Do not allow foreign materials to
enter the crankcase.
4. Start the engine, warm it up for several
minutes, and then turn it off.
5. Check:
• engine oil level
NOTE:
Before checking the engine oil level,
wait a few minutes until the oil has set-
tled.

3 - 26
CHK
ADJCHANGING THE ENGINE OIL/
CHECKING THE CLUTCH FLUID LEVEL
15.Install:
• front cowling
• bottom cowling
Refer to “COWLINGS”.
EB303100
CHECKING THE CLUTCH FLUID LEVEL
1. Stand the motorcycle on a level surface.
NOTE:
• Place the motorcycle on a suitable
stand.
• Make sure that the motorcycle is
upright.
2. Check:
• clutch fluid level
Below the minimum level mark a ®
Add the recommended clutch fluid to
the proper level.
WARNINGWARNING
• Use only the designated clutch fluid.
Other fluids may cause the rubber
seals to deteriorate, causing leakage
and poor clutch performance.
• Refill with the same type of fluid. Mix-
ing fluids may result in a harmful
chemical reaction leading to poor
clutch performance.
• When refilling, be careful that water
does not enter the clutch fluid reser-
voir. Water will significantly lower the
boiling point of the fluid and could
cause vapor lock.
ACHTUNG:CAUTION:
Clutch fluid may damage painted sur-
faces and plastic parts. Always clean up
any split fluid immediately.
NOTE:
In order to ensure a correct reading of
the clutch fluid level, make sure that the
top of the clutch fluid reservoir is hori-
zontal.
Recommended clutch fluid
Brake fluid DOT 4aa

3 - 27
CHK
ADJ
BLEEDING THE HYDRAULIC CLUTCH
SYSTEM
WARNINGWARNING
Bleed the hydraulic clutch system
whenever:
• the clutch system was disassembled,
• a clutch hose was loosened, discon-
nected or replaced,
• the clutch fluid level is very low,
• clutch operation is faulty.
NOTE:
• Be careful not to spill any clutch fluid
or allow the clutch fluid reservoir to
overflow.
• When bleeding the hydraulic clutch
system, make sure that there is always
enough clutch fluid before applying
the clutch. Ignoring this precaution
could allow air to enter the hydraulic
clutch system, considerably lengthen-
ing the bleeding procedure.
• If bleeding is difficult, it may be neces-
sary to let the clutch fluid settle for a
few hours. Repeat the bleeding proce-
dure when the tiny bubbles in the hose
have disappeared.
1. Bleed:
• hydraulic clutch system
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. Fill the clutch fluid reservoir to the
proper level with the recommended
clutch fluid.
b. Install the clutch fluid reservoir dia-
phragm.
c. Connect a clear plastic hose 1 tightly
to the bleed screw 2.
d. Place the other end of the hose into a
container.
e. Slowly apply the clutch several times.
f. Fully squeeze the clutch lever and
hold it in position.
g. Loosen the bleed screw.
NOTE:
Loosening the bleed screw will release
the pressure and cause the clutch lever
to contact the grip.
h. Tighten the bleed screw and then
release the clutch lever.
i. Repeat steps (e) to (h) until all of the
air bubbles have disappeared from
the clutch fluid in the plastic hose.
2
2
1
1

BLEEDING THE HYDRAULIC CLUTCH SYSTEM