Table Of Contents - Yamaha YZF-R7 Owner's Service Manual

Table of Contents

Introduction3
Particularly Important Information5
Finding The Required Page5
General5
Manual Format6
How To Read Descriptions6
Symbols7
Specifications7
Overhauling7
Cooling System7
Electronic Fuel7
Chassis7
Index9
Table Of Contents10
General Information13
Give Safety The Right Of Way13
Description14
Left View14
Right View14
Controls/Instruments15
Instrument And Control Functions16
Main Switch/Steering Lock16
Indicator Lights16
Fuel Indicator Light16
Warning Light17
Warning Light Circuit Check18
Fuel Indicator Light Circuit Check19
Selecting A Mode19
Odometer And Trip Meter Modes19
Resetting A Meter19
Digital Speedometer19
Clock Mode20
Tachometer20
To Set The Clock20
Diagnosis Device20
Lights Switch21
Dimmer Switch21
Handlebar Switches21
Turn Signal Switch21
Clutch Lever21
Shift Pedal22
Front Brake Lever22
Rear Brake Pedal22
Fuel Tank Cap22
Starter (Choke)23
Sidestand/Clutch Switch23
Operation And Important Riding Points24
Starting The Engine24
Starting A Warm Engine25
Engine Break-In26
Parking26
Included Accessories26
Tool Kit26
Motorcycle Care And Storage27
Before Cleaning27
After Normal Use27
After Cleaning28
Storage28
Short-Term28
Long-Term28
Consumer Information29
Identification Numbers Record29
Key Identification Number29
Vehicle Identification Number29
Model Label30
Troubleshooting Chart30
Engine Overheating31
Important Information32
Preparation For Removal And Disassembly32
Replacement Parts32
Gaskets, Oil Seals And O-Rings32
Using A Dynamometer33
Lock Washers/Plates And Cotter Pins33
Bearings And Oil Seals33
Circlips33
Checking The Connections34
Special Tools35
General Specifications39
Dimensions39
Weight39
Engine Specifications40
Oil Filter41
Oil Pump41
Spark Plugs41
Cylinder Head41
Camshafts42
Valves, Valve Seats, Valve Guides43
Timing Chain43
Valve Dimensions43
Valve Springs44
Valve Stem Runout44
Connecting Rods47
Crankshaft47
Clutch47
Transmission48
Shifting Mechanism48
Fuel Pump48
Chassis Specifications49
Rear Tire50
Front Brakes50
Rear Brake50
Front Suspension51
Electrical Specifications53
Tightening Torques55
General Tightening Torques55
Engine Tightening Torques56
Crankcase Tightening Sequence58
Chassis Tightening Torques59
Lubrication Points And Lubricant Types60
Engine Lubrication Points And Lubricant Types60
Chassis Lubrication Points And Lubricant Types61
Oil Flow Chart62
Coolant Flow Chart63
Cable Routing64
Periodic Checks And Adjustments70
Periodic Maintenance And Lubrication Intervals70
Periodic Maintenance And Lubrication71
Fuel Tank And Air Filter73
Removing The Fuel Tank And Air Filter73
Cowlings75
Removing The Front Cowling75
Removing The Rear Cowling76
Adjusting The Valve Clearance78
Engine78
Valve Pad Selection Table82
Intake82
Exhaust82
Synchronizing The Throttle Bodies83
Adjusting The Engine Idling Speed85
Adjusting The Throttle Cable Free Play86
Checking The Spark Plugs88
Handlebar Side88
Measuring The Compression Pressure89
Checking The Engine Oil Level92
Changing The Engine Oil93
Checking The Clutch Fluid Level95
Bleeding The Hydraulic Clutch System96
Cleaning The Air Filter Element97
Checking The Fuel Hoses98
Checking The Crankcase Breather Hose98
Checking The Exhaust System99
Checking The Coolant Level100
Checking The Cooling System101
Changing The Coolant102
Adjusting The Rear Brake105
Checking The Brake Fluid Level106
Checking The Brake Pads107
Checking The Brake Hoses108
Bleeding The Hydraulic Brake System108
Adjusting The Shift Pedal110
Adjusting The Drive Chain Slack110
Lubricating The Drive Chain112
Checking And Adjusting The Steering Head112
Recommended Lubricant112
Lower Ring Nut114
Steering Head Tension115
Checking The Front Fork115
Adjusting The Front Fork Legs116
Spring Preload116
Rebound Damping117
Compression Damping117
Adjusting Positions117
Adjusting The Rear Shock Absorber Assembly118
Minimum Tire Tread Depth121
Front Tire121
Checking The Tires122
Checking The Wheels122
Checking And Lubricating The Cables123
Lubricating The Levers And Pedals123
Lubricating The Sidestand123
Lubricating The Rear Suspension123
Electrical System124
Checking And Charging The Battery124
Charging Method Using A Variable-Voltage Charger127
Charging Method Using A Constant-Voltage Charger128
Checking The Fuses129
Replacing The Headlight Bulbs131
Adjusting The Headlight Beams132
Overhauling The Engine133
Removing The Drive Sprocket133
Removing The Exhaust Assembly135
Disconnecting The Leads And Hoses136
Installing The Engine139
Removing The Cylinder Head Cover140
Removing The Camshafts141
Installing The Camshafts147
Removing The Cylinder Head150
Checking The Cylinder Head151
Installing The Cylinder Head152
Valves And Valve Springs153
Removing The Valves And Valve Springs153
Removing The Valves155
Checking The Valves And Valve Guides156
Checking The Valve Springs160
Valve Spring Free Length160
Inner Spring160
Compressed Spring Force161
Maximum Spring Tilt161
Checking The Valve Lifters161
Installing The Valves162
Generator164
Removing The Stator Coil Assembly164
Removing The Generator165
Installing The Generator165
Pickup Coil167
Removing The Pickup Coil And Pickup Coil Rotor167
Removing The Pickup Coil Rotor169
Installing The Pickup Coil Rotor169
Removing The Clutch Cover171
Removing The Clutch172
Checking The Friction Plates174
Checking The Clutch Plates175
Checking The Clutch Spring Plate175
Checking The Clutch Housing175
Checking The Clutch Boss176
Checking The Pressure Plate176
Checking The Push Rods And Ball176
Checking The Back Torque Limiter176
Checking The Starter Clutch177
Installing The Clutch178
Shift Shaft180
Removing The Shift Shaft And Stopper Lever180
Checking The Shift Shaft181
Checking The Stopper Lever181
Installing The Shift Shaft181
Oil Pan And Oil Pump182
Removing The Oil Pan And Oil Pump182
Removing The Oil Pan185
Removing The Oil Pump185
Checking The Oil Pump185
Checking The Relief Valve186
Checking The Oil Strainer186
Assembling The Oil Pump186
Installing The Oil Pump187
Installing The Oil Strainer187
Installing The Oil Pan187
Crankcase188
Separating The Crankcase188
Removing The Oil Baffle Plates And Oil Filter Bolt190
Disassembling The Crankcase191
Checking The Crankcase192
Checking The Bearings And Oil Seals192
Checking The Sprockets And Chains192
Assembling The Crankcase193
Connecting Rods And Pistons195
Removing The Connecting Rods And Pistons195
Checking The Cylinders And Pistons197
Checking The Piston Rings198
Checking The Piston Pins199
Checking The Big End Bearings200
Installing The Pistons And Connecting Rods202
Big End Bearing Color Code202
Removing The Crankshaft Assembly206
Removing The Crankshaft207
Checking The Crankshaft207
Checking The Crankshaft Journal Bearings207
Removing The Transmission217
Checking The Shift Forks217
Checking The Shift Drum Assembly218
Checking The Transmission218
Transmission Gears218
Transmission Gear Dogs218
Installing The Transmission219
Radiator And Thermostat220
Removing The Radiator220
Removing The Thermostat Assembly222
Disassembling The Thermostat Assembly224
Checking The Radiator225
Radiator Cap Opening Pressure225
Radiator Cap Tester225
Assembling The Thermostat Assembly226
Installing The Thermostat Assembly And Radiator227
Oil Cooler228
Removing The Oil Cooler228
Checking The Oil Cooler229
Installing The Oil Cooler229
Water Pump231
Removing The Impeller Shaft231
Disassembling The Water Pump233
Checking The Water Pump233
Assembling The Water Pump234
Electronic Fuel Injection236
Removing The Injector 2 Assembly And Air Filter Case236
Removing The Injector 2238
Electronic Fuel Injection Efi238
Removing The Throttle Body Assembly240
Removing The Injector 1 And Throttle Body242
Checking The Injector244
Checking The Throttle Body244
Checking The Pressure Regulator245
Checking And Adjusting The Throttle Position Sensor245
Checking The Fuel Pump And Pressure Regulator Operation249
Front Wheel And Brake Discs251
Removing The Front Wheel And Brake Discs251
Disassembling The Front Wheel252
Removing The Front Wheel253
Checking The Front Wheel253
Checking The Brake Discs255
Installing The Front Wheel256
Adjusting The Front Wheel Static Balance257
Rear Wheel, Brake Disc, And Rear Wheel Sprocket259
Removing The Rear Wheel259
Removing The Brake Disc And Rear Wheel Sprocket260
Disassembling The Rear Wheel261
Checking The Rear Wheel262
Checking The Rear Wheel Drive Hub263
Checking And Replacing The Rear Wheel Sprocket263
Installing The Rear Wheel264
Adjusting The Rear Wheel Static Balance264
Front And Rear Brakes265
Removing The Front Brake Pads265
Removing The Rear Brake Pads266
Replacing The Front Brake Pads267
Replacing The Rear Brake Pads269
Removing The Front Brake Calipers272
Disassembling The Front Brake Calipers273
Removing The Rear Brake Caliper274
Disassembling The Rear Brake Caliper275
Checking The Front And Rear Brake Calipers278
Recommended Brake Component Replacement Schedule278
Assembling And Installing The Front Brake Calipers279
Assembling And Installing The Rear Brake Caliper281
Recommended Brake Fluid282
Removing The Front Brake Master Cylinder And Brake Fluid Reservoir283
Disassembling The Front Brake Master Cylinder285
Removing The Rear Brake Master Cylinder And Brake Fluid Reservoir286
Disassembling The Rear Brake Master Cylinder287
Checking The Front And Rear Brake Master Cylinders288
Assembling And Installing The Front Brake Master Cylinder289
Assembling The Rear Brake Master Cylinder291
Hydraulic Clutch293
Removing The Clutch Master Cylinder293
Disassembling The Clutch Master Cylinder295
Checking The Clutch Master Cylinder296
Assembling And Installing The Clutch Master Cylinder297
Removing The Clutch Release Cylinder300
Disassembling The Clutch Release Cylinder301
Assembling And Installing The Clutch Release Cylinder303
Front Fork305
Removing The Front Fork Legs305
Disassembling The Front Fork Legs306
Checking The Front Fork Legs310
Assembling The Front Fork Legs311
Installing The Front Fork Legs316
Handlebars317
Removing The Handlebars317
Checking The Handlebars319
Installing The Handlebars319
Steering Head322
Removing The Lower Bracket322
Checking The Steering Head324
Installing The Steering Head325
Rear Shock Absorber Assembly326
Removing The Rear Shock Absorber Assembly326
Handling The Rear Shock Absorber And Gas Cylinder327
Disposing Of A Rear Shock Absorber And Gas Cylinder327
Checking The Rear Shock Absorber Assembly And Gas Cylinder328
Checking The Relay Arm And Connecting Arm329
Installing The Rear Shock Absorber Assembly329
Swingarm And Drive Chain330
Removing The Swingarm And Drive Chain330
Removing The Swingarm332
Removing The Drive Chain333
Checking The Swingarm333
Checking The Drive Chain334
Installing The Swingarm336
Electrical Components337
Switches338
Checking Switch Continuity338
Checking The Switches339
Checking The Bulbs And Bulb Sockets340
Checking The Condition Of The Bulbs340
Checking The Condition Of The Bulb Sockets342
Checking The Leds342
Ignition System343
Circuit Diagram343
Troubleshooting344
Measuring The Ignition Spark Gap345
Minimum Ignition Spark Gap345
Measuring The Ignition Coil Resistance346
Measuring The Pickup Coil Resistance346
Checking The Diode347
Checking The Relay Unit347
Electric Starting System348
The Starter Motor Fails To Turn349
Checking The Starter Relay351
Checking The Diodes351
Charging System352
The Battery Is Not Being Charged353
Measuring The Charging Voltage354
Measuring The Stator Coil Assembly Resistances354
Lighting System355
Signaling System357
Checking The Oil Level Switch359
Pocket Tester359
Checking The Thermo Switch362
Electronic Fuel Injection System364
The Condition Code Is Displayed By The Tachometer365
Electrical Control System366
User Mode366
Tachometer Display Sequence (Engine Not Running)367
Condition Code List368
Diagnosis Mode369
Co, Diagnosis Switch Box Method369
Operation After Entering The Diagnosis Mode370
Test Coupler Adapter Method371
Diagnosis Code List372
Co Emission Adjustment Mode375
Exhaust Attachment375
Engine Tachometer375
Co, Diagnosis Switch Box375
Standard Co Concentration377
Yzf-R7 Wiring Diagram378
Color Code378