1999 YAMAHA YZF-R7 wheel

EB004000
SYMBOLS
The following symbols are not relevant to
every vehicle.
Symbols
1
to
9
indicate the subject of
each chapter.
1
General information
2
Specifications
3
Periodic checks and adjustments
4
Overhauling the engine
5
Cooling system
6
Electronic fuel injection
7
Chassis
8
Electrical
Symbols
9
to
F
indicate the following.
9
Serviceable with engine mounted
0
Filling fluid
A
Lubricant
B
Special tool
C
Tightening torque
D
Wear limit, clearance
E
Engine speed
F
Electrical data
Symbols
G
to
L
in the exploded diagrams
indicate the types of lubricants and lubrica-
tion points.
G
Engine oil
H
Gear oil
I
Molybdenum disulfide oil
J
Wheel bearing grease
K
Lithium soap base grease
L
Molybdenum disulfide grease
Symbols
M
to
N
in the exploded diagrams
indicate the following.
MApply locking agent (LOCTITE
â)
NReplace the part 12
34
56
78
90
AB
CD
E F
GHI
JKL
M N
SPEC
CHK
ADJENG
COOLEFI
CHAS–+ELEC
T R..
GME
BLSM
LTNew

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 - 15
MOTORCYCLE CARE AND STORAGE
Care
The exposure of its technology makes
a motorcycle charming but also vulner-
able. Although high-quality compo-
nents are used, they are not all rust-
resistant. While a rusty exhaust pipe
may remain unnoticed on a car, it does
look unattractive on a motorcycle. Fre-
quent and proper care, however, will
keep your motorcycle looking good, ex-
tend its life and maintain its perfor-
mance. Moreover, the warranty states
that the vehicle must be properly taken
care of. For all these reasons, it is rec-
ommended that you observe the fol-
lowing cleaning and storing
precautions.Before cleaning
1. Cover up the muffler outlet with a
plastic bag.
2. Make sure that all caps and cov-
ers as well as all electrical cou-
plers and connectors, including
the spark plug caps, are tightly in-
stalled.
3. Remove extremely stubborn dirt,
like oil burnt onto the crankcase,
with a degreasing agent and a
brush, but never apply such prod-
ucts onto seals, gaskets, sprock-
ets, the drive chain and wheel
axles. Always rinse the dirt and
degreaser off with water.Cleaning
After normal useRemove dirt with warm water, a neutral
detergent and a soft clean sponge,
then rinse with plenty of clean water.
Use a tooth or bottle brush for hard-to-
reach parts. Tougher dirt and insects
will come off more easily if the area is
covered with a wet cloth for a few min-
utes before cleaning.
MOTORCYCLE CARE AND STORAGE
ECA00010
CAUTION:
lAvoid using strong acidic
wheel cleaners, especially on
spoked wheels. If you do use
such products for hard-to-re-
move dirt, do not leave it on any
longer than instructed, then
thoroughly rinse it off with wa-
ter, immediately dry the area
and apply a corrosion protec-
tion spray.
lImproper cleaning can damage
windshields, cowlings, panels
and other plastic parts. Use
only a soft, clean cloth or
sponge with mild detergent and
water to clean plastic.
lDo not use any harsh chemical
products on plastic parts. Be
sure to avoid using cloths or
sponges which have been in
contact with strong or abrasive
cleaning products, solvent or
thinner, fuel (gasoline), rust re-
movers or inhibitors, brake flu-
id, antifreeze or electrolyte.
lDo not use high-pressure
washers or steam-jet cleaners
since they cause water seep-
age and deterioration in the fol-
lowing areas: seals (of wheel
bearings, swingarm bearings,
forks and brakes), electric com-
ponents (couplers, connectors,
instruments, switches and
lights), breather hoses and
vents.
lFor motorcycles equipped with
a windshield: Do not use strong
cleaners or hard sponges as
they will cause dulling or
scratching. Some cleaning
compounds for plastic may
leave scratches on the wind-
shield. Test the product on a
small hidden part of the wind-
shield to make sure they do not
leave any marks. If the wind-
shield is scratched, use a quali-
ty plastic polishing compound
after washing.
lDo not rub the frame, swingarm
and other similar matte metal
parts with a cloth (neither one
dampened with solvents or
gasoline nor a dry one), as this
may deteriorate their finish.
Wash off dirt with water only.
For hard-to-remove dirt, add a
mild detergent and rub only
lightly.
After riding in the rain, near the sea or
on salt-sprayed roads
Since sea salt or salt sprayed on the
roads in the winter are extremely corro-
sive in combination with water, carry
out the following steps after each ride
in the rain, near the sea or on salt-
sprayed roads. (Salt sprayed in the
winter may remain on the roads well
into spring.)

1 - 17
MOTORCYCLE CARE AND STORAGE/
CONSUMER INFORMATION
WARNING
When using the starter motor to
crank the engine, remove the spark
plug wires, and ground them to pre-
vent sparking.
4. Remove the drive chain. Thor-
oughly clean the chain with kero-
sene and lubricate it. Reinstall the
chain or store it in a plastic bag
(tied to frame for safekeeping).
5. Lubricate all control cables.
6. Block up the frame to raise both
wheels off the ground.
7. Tie a plastic bag over the exhaust
pipe outlet to prevent moisture
from entering.
8. If strong in a humid or salt-air at-
mosphere, coat all exposed metal
surfaces with a light film of oil. Do
not apply oil to any rubber parts or
the seat cover.9. Remove the battery and charge it.
Store it in a dry place and re-
change it once a month. Do not
store the battery in an excessively
warm or cold place (less than 0°C
(30°F) or more than 30°C (90°F)).
NOTE:
Make any necessary repairs before
storing the motorcycle.
CONSUMER INFORMATION
EAU01040
Identification numbers record
Record the key identification number,
vehicle identification number and mod-
el label information in the spaces pro-
vided for assistance when ordering
spare parts from a Yamaha dealer or
for reference in case the vehicle is sto-
len.
1. KEY IDENTIFICATION
NUMBER:
2. VEHICLE IDENTIFICATION
NUMBER:
3. MODEL LABEL INFORMATION:
1. Key identification numberEAU01041
Key identification number
The key identification number is
stamped on the key tag. Record this
number in the space provided and use
it for reference when obtaining a new
key.
1. Vehicle identification numberEAU01043
Vehicle identification number
The vehicle identification number is
stamped into the steering head pipe.
Record this number in the space pro-
vided.
NOTE:
The vehicle identification number is
used to identify your motorcycle and
may be used to register your motorcy-
cle with the licensing authority in your
state.

1 - 23
SPECIAL TOOLS
EB104000
SPECIAL TOOLS
The following special tools are necessary for complete and accurate tune-up and assembly.
Use only the appropriate special tools as this will help prevent damage caused by the use of
inappropriate tools or improvised techniques.
When placing an order, refer to the list provided below to avoid any mistakes.
Tool No. Tool name/Function Illustration
90890-01080Flywheel puller
This tool is used to remove the generator
rotor.
90890-01235Rotor holding tool
This tool is used to hold the generator
rotor when removing or installing the gen-
erator rotor bolt or pickup coil rotor bolt.
90890-01286Drive chain cutter
This tool is used to remove the drive
chain.
90890-01304Piston pin puller
This tool is used to remove the piston
pins.
Radiator cap
tester
90890-01325
Adapter
90890-01352Radiator cap tester
Adapter
These tools are used to check the cooling
system.
90890-01403Steering nut wrench
This tool is used to loosen or tighten the
steering stem ring nuts.
90890-01426Oil filter wrench
This tool is needed to loosen or tighten
the oil filter cartridge.
90890-01434Rod holder
This tool is used to support the damper
adjusting rod.

GENERAL SPECIFICATIONS
SPEC

2 - 1
SPECIFICATIONS
GENERAL SPECIFICATIONS
Item Standard Limit
Dimensions
Overall length 2,060 mm (81.1 in) ----
Overall width 720 mm (28.3 in) ----
Overall height 1,125 mm (44.3 in) ----
Seat height 840 mm (33.1 in) ----
Wheelbase 1,400 mm (55.1 in) ----
Minimum ground clearance 120 mm (4.72 in) ----
Minimum turning radius 3,800 mm (150 in) ----
Weight
Wet (with oil and a full fuel tank) 207 kg (456 lb) ----
Dry (without oil and fuel) 176 kg (388 lb) ----
Maximum load (total of rider and
accessories) 317 kg (699 lb) ----
2

CHASSIS SPECIFICATIONS
SPEC

2 - 11
CHASSIS SPECIFICATIONS
Item Standard Limit
Frame
Frame type Diamond ----
Caster angle 22.7˚ ----
Trail 95 mm (3.74 in) ----
Front wheel
Wheel type Cast wheel ----
Rim
Size 17
´
MT3.50 ----
Material Aluminum ----
Wheel travel 120 mm (4.72 in) ----
Wheel runout
Maximum radial wheel runout ---- 1 mm
(0.04 in)
Maximum lateral wheel runout ---- 0.5 mm
(0.02 in)
Rear wheel
Wheel type Cast wheel ----
Rim
Size 17
´
MT6.00 ----
Material Aluminum ----
Wheel travel 138 mm (5.43 in) ----
Wheel runout
Maximum radial wheel runout ---- 1 mm
(0.04 in)
Maximum lateral wheel runout ---- 0.5 mm
(0.02 in)
Front tire
Tire type Tubeless ----
Size 120/70 ZR17 (58W) ----
Model (manufacturer) MTR01A (PIRELLI) ----
Tire pressure (cold)
0 ~ 90 kg (0 ~ 198 lb) 250 kPa (2.5 kg/cm
2

, 3.6 psi) ----
90 kg (198 lb) ~ Maximum load* 250 kPa (2.5 kg/cm
2

, 3.6 psi) ----
High-speed riding 250 kPa (2.5 kg/cm
2

, 3.6 psi) ----
* Load is the total weight of the rider
and accessories.
Minimum tire tread depth ---- 1.6 mm
(0.06 in)

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