1999 YAMAHA YZF-R7 transmission

4 - 85
ENGTRANSMISSION
EB413100
REMOVING THE TRANSMISSION
1. Remove:
• main axle assembly 1
(with the Torx
Ò wrench T30)
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. Insert two bolts 2 of the proper size,
as shown in the illustration, into the
main axle assembly bearing housing.
b. Tighten the bolts until they contact
the crankcase surface.
c. Continue tightening the bolts until the
main axle assembly comes free from
the upper crankcase.
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
EB413400
CHECKING THE SHIFT FORKS
The following procedure applies to all of
the shift forks.
1. Check:
• shift fork cam follower 1
• shift fork pawl 2
Bends/damage/scoring/wear ®
Replace the shift fork.
2. Check:
• shift fork guide bar
Roll the shift fork guide bar on a flat
surface.
Bends ® Replace.
WARNINGWARNING
Do not attempt to straighten a bent
shift fork guide bar.

4 - 86
ENGTRANSMISSION
3. Check:
• shift fork movement
(along the shift fork guide bar)
Rough movement ® Replace the shift
fork(-s) and shift fork guide bar as a
set.
EB413410
CHECKING THE SHIFT DRUM ASSEMBLY
1. Check:
• shift drum grooves
Damage/scratches/wear ® Replace the
shift drum assembly.
• shift drum segment 1
Damage/wear ® Replace the shift
drum assembly.
• shift drum bearing 2
Damage/pitting ® Replace the shift
drum assembly.
EB413422
CHECKING THE TRANSMISSION
1. Measure:
• main axle runout
(with a centering device and dial
gauge 1)
Out of specification ® Replace the
main axle.
Maximum main axle runout
0.08 mm (0.003 in)
2. Measure:
• drive axle runout
(with a centering device and dial
gauge 1)
Out of specification ® Replace the
drive axle.
Maximum drive axle runout
0.08 mm (0.003 in)
3. Check:
• transmission gears
Blue discoloration/pitting/wear ®
Replace the defective gear(-s).
• transmission gear dogs
Cracks/damage/rounded edges ®
Replace the defective gear(-s).

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.

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–+ELECELECTRICAL CONTROL SYSTEM
Condition code list
NOTE:
* This condition code is also displayed in the following cases:
- when the starter switch is held down for more than 4 seconds, causing the warning
light to flash
- when the ignition circuit cut-off system stops the engine or prevents it from starting
** This condition code is also displayed when the engine is operated at 5,000 r/min for at
least 30 seconds with the rear wheel at standstill.
*** This condition code is also displayed when the engine stop switch is turned to “ ”
while riding with the transmission in gear. Condition
codeCircuit Defect(s) System response
11 Camshaft sensor • No incoming sig-
nalThe ECU pairs the ignition of cyl-
inders #1 and #4 and cylinders #2
and #3. The motorcycle can be
ridden.
12* Pickup coil • No incoming sig-
nalThe motorcycle cannot be ridden.
13 Intake air pressure
sensor• Disconnected
• Short-circuitThe ECU stays set to an intake air
pressure of 760 mm Hg (29.9 in Hg).
The motorcycle can be ridden.
14 Intake air pressure
sensor hose and
negative pressure
hose• Improper connec-
tion
• Bending
15 Throttle position
sensor• Disconnected
• Short-circuitThe ECU stays set to a wide throt-
tle opening.
The motorcycle can be ridden.
16 Throttle position
sensor• Locked
21 Coolant tempera-
ture sensor• Disconnected
• Short-circuitThe ECU stays set to a coolant
temperature of 80˚C (176˚F).
The motorcycle can be ridden.
22 Intake air tempera-
ture sensor• Disconnected
• Short-circuitThe ECU stays set to an intake air
temperature of 40˚C (104˚F).
The motorcycle can be ridden.
23 Atmospheric pres-
sure sensor• Disconnected
• Short-circuitThe ECU stays set to an atmo-
spheric pressure of 760 mm Hg
(29.9 in Hg).
The motorcycle can be ridden.
41 Fall detection
switch• Disconnected The main relay stays switched off.
The motorcycle cannot be ridden.
42** Speed sensor • Incorrect signal The ECU stays set to 6th gear.
The motorcycle can be ridden.
43*** Monitored voltage • Incorrect The ECU stays set to a monitored
voltage of 12 V.
The motorcycle can be ridden.
44 ROM operation • CO emission
adjustment errorThe CO emission adjustment is
set to 0.