1999 YAMAHA YZF-R7 engine coolant

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

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 - 5
INSTRUMENT AND CONTROL FUNCTIONS
4 681012
14
x1000r/min
0
1 12
3 3
4

1. Warning light
2. Oil level symbol “ ”
3. Coolant temperature symbol “ ”
4. Engine trouble symbol “ ”
EAU01564
Warning light
This indicator light has three functions.
l
The light will come on and symbol
“ ” will flash if the engine oil
level is low.
If this symbol flashes, stop the en-
gine immediately and fill it with oil
to the specified level.
l
The light will come on and symbol
“ ” will flash if trouble occurs in
a monitoring circuit. In such a
case, take the motorcycle to a
Yamaha dealer to have the self-
diagnostic systems checked.
l
The light will come on and symbol
“ ” will flash if the coolant tem-
perature is too high. The following
chart shows the conditions of the
indicator light, symbol and tem-
perature display in accordance to
coolant temperature.
The light circuit can be checked by the
procedure on page 1-6.
EC000118
CAUTION:

l
Do not run the motorcycle until
you know it has sufficient en-
gine oil.
l
Do not run the motorcycle if the
engine is overheated.
NOTE:

Even if the oil is filled to the specified
level, the indicator light may flicker
when riding on a slope or during sud-
den acceleration or deceleration, but
this is normal.
CB-74ECB-74E
Coolant
temperatureDisplay Conditions What to do
~ 39 ˚CSymbol is on and “LO” is
displayed.OK. Go ahead with riding.
40 ˚C ~ 120 ˚CSymbol is on and temper-
ature is displayed.OK. Go ahead with riding.
121 ˚C ~ 139 ˚CSymbol and temperature
flash.
Warning light comes on.Stop the motorcycle and al-
low it to idle until coolant tem-
perature goes down.
If the temperature does not
go down, stop the engine.
140 ˚C ~ Symbol and message
“HI” flash.
Warning light comes on.Stop the engine and allow it
to cool. Seen page 1-19 if the
engine overheats.
—Symbol and message
“Err” flash.
Warning light comes on.Ask a Yamaha dealer to in-
spect the motorcycle.
C
C
C
C
C

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.

ENGINE SPECIFICATIONS
SPEC

2 - 3
Oil filter
Oil filter type Cartridge (paper) ----
Bypass valve opening pressure 180 ~ 220 kPa
(1.8 ~ 2.2 kgf/cm
2

, 25.6 ~ 31.3 psi)----
Oil pump

Oil pump type Trochoidal ----
Inner rotor-to-outer rotor tip clear-
ance0.09 ~ 0.15 mm (0.004 ~ 0.006 in) ----
Outer rotor-to-oil pump housing
clearance0.03 ~ 0.08 mm (0.001 ~ 0.003 in) ----
Cooling system
Radiator capacity 2.75 L (2.42 Imp qt, 2.91 US qt)
Radiator cap opening pressure 95 ~ 125 kPa
(0.95 ~ 1.25 kgf/cm
2

, 13.1 ~ 17.8 psi)----
Upper radiator core
Width 414 mm (16.3 in) ----
Height 248 mm (9.76 in) ----
Depth 24 mm (0.94 in) ----
Lower radiator core
Width 211 mm (8.31 in) ----
Height 158 mm (6.22 in) ----
Depth 24 mm (0.94 in) ----
Coolant reservoir
Capacity 0.6 L (0.53 Imp qt, 0.63 US qt) ----
Water pump
Water pump type Single-suction centrifugal pump ----
Reduction ratio 88/47
´
28/25 (2.097) ----
Maximum impeller shaft tilt ---- 0.15 mm
(0.006 in)
Starting system type
Electric starter
Spark plugs
Model (manufacturer)
´
quantity R0256R-10 (NGK)
´
4 ----
Spark plug gap 0.7 ~ 0.8 mm (0.028 ~ 0.031 in) ----
Cylinder head
Maximum warpage ---- 0.06 mm
(0.0024 in) Item Standard Limit

2 - 21
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

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 - 31
CHK
ADJ
CHECKING THE COOLANT LEVEL
EB303220
CHECKING THE COOLANT 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. Remove:
• bottom cowling
• front cowling
Refer to “COWLINGS”.
3. Check:
• coolant level
The coolant level should be between
the minimum level mark a and maxi-
mum level mark b.
Below the minimum level mark ® Add
the recommended coolant to the
proper level.
ACHTUNG:CAUTION:
• Adding water instead of coolant lowers
the antifreeze content of the coolant. If
water is used instead of coolant, check
and if necessary, correct the antifreeze
concentration of the coolant.
• Use only distilled water. However,
soft water may be used if distilled
water is not available.
4. Start the engine, warm it up for several
minutes, and then turn it off.
5. Check:
• coolant level
NOTE:
Before checking the coolant level, wait a
few minutes until the coolant has set-
tled.
aa b
b