1999 YAMAHA YZF-R7 heating

1 - 6
INSTRUMENT AND CONTROL FUNCTIONS
Warning light circuit check
CB-75ECB-75E
Warning light comes on. After a few seconds:Warning light does not come on.
Have a Yamaha
dealer inspect the
electrical circuit.
Turn the main switch to “ON”.
Have a Yamaha dealer inspect
the electrical circuit.
If symbol “ ” is on, check the
engine temperature. (See page 1-5.)
Warning light goes off.
No symbol is on.Symbol “ ”,
“ ” “ ” is on.
OK. Go ahead
with riding.
Warning light does not go off.
If symbol “ ”
is on, inspect the
oil level.
Oil level is OK.Oil level is low.
Have a Yamaha dealer
inspect the electrical
circuit.Supply
recommended
engine oil.
If the engine is hot,
allow it to cool and see
“Engine overheating”
in the troubleshooting
chart on page 1-19 for
instructions.If the engine
temperature is
normal, have a
Yamaha dealer
inspect the
electrical circuit.
If symbol “ ” is on.
Have a Yamaha dealer
inspect the self-
diagnostic systems.

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OPERATION AND IMPORTANT RIDING POINTS/
INCLUDED ACCESSORIES
EAU01128
Engine break-in
There is never a more important period
in the life of your motorcycle than the
period between zero and 1,600 km. For
this reason we ask that you carefully
read the following material. Because
the engine is brand new, you must not
put an excessive load on it for the first
1,600 km. The various parts in the en-
gine wear and polish themselves to the
correct operating clearances. During
this period, prolonged full throttle oper-
ation, or any condition which might re-
sult in excessive heating of the engine,
must be avoided.
EAU013290 ~ 1,000 km
Avoid operation above 5,500 r/min.
1,000 ~ 1,600 km
Avoid cruising speeds in excess of
7,000 r/min.
EC000052
CAUTION:
After 1,000 km of operation, be sure
to replace the engine oil and oil fil-
ter.
1,600 km and beyond
Proceed with normal riding.
EC000053
CAUTION:
lNever let engine speeds enter
the red zone.
lIf any engine trouble should oc-
cur during the break-in period,
consult a Yamaha dealer imme-
diately.
EAU00460
Parking
When parking the motorcycle, stop the
engine and remove the ignition key.
EW000058
WARNING
The exhaust system is hot. Park the
motorcycle in a place where pedes-
trians or children are not likely to
touch the motorcycle. Do not park
the motorcycle on a slope or soft
ground; the motorcycle may over-
turn.
INCLUDED ACCESSORIES
EAU01575
Tool kit
The tools provided in the owner’s tool
kit are to assist you in the performance
of periodic maintenance. However,
some other tools such as a torque
wrench are also necessary to perform
the maintenance correctly.
The service information included in this
manual is intended to provide you, the
owner, with the necessary information
for completing some of your own pre-
ventive maintenance and minor re-
pairs.
NOTE:
If you do not have necessary tools re-
quired during a service operation, take
your motorcycle to a Yamaha dealer
for service.
EW000063
WARNING
Modifications to this motorcycle not
approved by Yamaha may cause
loss of performance, and render it
unsafe for use. Consult a Yamaha
dealer before attempting any chang-
es.

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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.

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CHK
ADJBLEEDING THE HYDRAULIC CLUTCH SYSTEM/
CLEANING THE AIR FILTER ELEMENT
j. Tighten the bleed screw to specifica-
tion.
k. Fill the clutch fluid reservoir to the
proper level with the recommended
clutch fluid.
Refer to “CHECKING THE CLUTCH
FLUID LEVEL”.
WARNINGWARNING
After bleeding the hydraulic clutch sys-
tem, check the clutch operation.
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..
Bleed screw
6 Nm (0.6 m • kg, 4.3 ft • lb)
EB303130
CLEANING THE AIR FILTER ELEMENT
1. Remove:
• fuel tank
• air filter case cover
• air filter element
Refer to “FUEL TANK AND AIR FIL-
TER”.
2. Clean:
• air filter element
Apply compressed air to the outer sur-
face of the air filter element.
3. Check:
• air filter element
Damage ® Replace.
4. Install:
• air filter element
• air filter case cover
ACHTUNG:CAUTION:
Never operate the engine without the
air filter element installed. Unfiltered air
will cause rapid wear of engine parts
and may damage the engine. Operating
the engine without the air filter element
will also affect the electronic fuel injec-
tion, leading to poor engine perfor-
mance and possible overheating.
5. Install:
• fuel tank
Refer to “FUEL TANK AND AIR FIL-
TER”.

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CHK
ADJ
5. Charge:
• battery
(refer to the appropriate charging
method illustration)
WARNINGWARNING
Do not quick charge a battery.
ACHTUNG:CAUTION:
• Never remove the MF battery sealing
caps.
• Do not use a high-rate battery charger
since it forces a high-amperage cur-
rent into the battery quickly and can
cause battery overheating and bat-
tery plate damage.
• If it is impossible to regulate the
charging current on the battery
charger, be careful not to overcharge
the battery.
• When charging a battery, be sure to
remove it from the motorcycle. (If
charging has to be done with the bat-
tery mounted on the motorcycle, dis-
connect the negative lead from the
battery terminal.)
• To reduce the chance of sparks, do not
plug in the battery charger until the
battery charger leads are connected to
the battery.
• Before removing the battery charger
lead clips from the battery terminals,
be sure to turn off the battery charger.
• Make sure that the battery charger
lead clips are in full contact with the
battery terminal and that they are not
shorted. A corroded battery charger
lead clip may generate heat in the con-
tact area and a weak clip spring may
cause sparks.
• If the battery becomes hot to the
touch at any time during the charging
process, disconnect the battery
charger and let the battery cool before
reconnecting it. Hot batteries can
explode!
• As shown in the following illustration,
the open-circuit voltage of an MF bat-
tery stabilizes about 30 minutes after
charging has been completed. There-
fore, wait 30 minutes after charging is
completed before measuring the
open-circuit voltage.
(68 ˚F)
(68 ˚F)
CHECKING AND CHARGING THE BATTERY

5 - 7
COOL

RADIATOR AND THERMOSTAT
EB502020
CHECKING THE THERMOSTAT
1. Check:
• thermostat
1

Does not open at 71 ~ 85 ˚C (159.8 ~
185 ˚F)
®
Replace.
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. Suspend the thermostat in a con-
tainer filled with water.
b. Slowly heat the water.
c. Place a thermometer in the water.
d. While stirring the water, observe the
thermostat and thermometer’s indi-
cated temperature.
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
1
Thermostat
2
Thermometer
3
Water
4
Container

Fully closed
õ
Fully open
NOTE:

If the accuracy of the thermostat is in
doubt, replace it. A faulty thermostat
could cause serious overheating or
overcooling.
2. Check:
• thermostat housing cover
• thermostat housing
Cracks/damage
®
Replace.
EB502030
ASSEMBLING THE THERMOSTAT
ASSEMBLY
1. Install:
• thermostat housing
1

• thermostat
2

• thermostat housing cover
NOTE:

Install the thermostat with its breather
hole
a
facing up.
2
1
1
2
a a

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–+ELECCOOLING SYSTEM
CHECKING THE THERMO SWITCH
• Remove the thermo switch from the radia-
tor.
• Connect the pocket tester (W ´ 1) to the
thermo switch 1 as shown.
• Immerse the thermo switch in a container
filled with coolant 2.
NOTE:
Make sure that the thermo switch terminals
do not get wet.
• Place a thermometer 3 in the coolant.
• Slowly heat the coolant, then let it cool to
the specified temperature as indicted in
the table.
• Check the thermo switch for continuity a
the temperatures indicated in the table.
WARNINGWARNING
• Handle the thermo switch with special
care.
• Never subject the thermo switch to
strong shocks. If the thermo switch is
dropped, replace it.
The thermo switch circuit is open and the
radiator fan is off.
õThe thermo switch circuit is closed and the
radiator fan is on.
• Does the thermo switch operate properly
as described above?
Yes ® OK.
No ® Replace.
Test stepCoolant temperature
Continuity
Thermo switch
10 ~ 100 ± 3˚C
(0 ~ 212 ± 37.4˚F)NO
2
More than 105 ± 3˚C
(221 ± 37.4˚C)YES
3*
105 to 100 ˚C
(221 to 212 ˚F)YES
4*
Less than 100 ˚C (212 ˚F)NO
Test steps 1 & 2: Heating phase
Test steps 3* & 4*: Cooling phase
T R..
Thermo switch
23 Nm (2.3 m • kg, 17 ft • lb)
Three bond sealock
® 10