Yamaha R7 2022 User manual

2022
SERVICE MANUAL
R7
YZF690
YZF690-U
BEB-28197-E0

EAS20003
IMPORTANT
This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers
and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one man-
ual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles
should have a basic understanding of mechanics and the techniques to repair these types of vehicles.
Please refer to “BASIC INFORMATION” (separate volume, Y0A-28197-E0*) for basic instructions that
must be observed during servicing.
Repair and maintenance work attempted by anyone without this knowledge is likely to render the vehi-
cle unsafe and unfit for use.
Yamaha Motor Company, Ltd. is continually striving to improve all of its models. Modifications and sig-
nificant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and
will appear in future editions of this manual where applicable.
TIP
•*Ifthecontentsofthemanualarerevised,thelast digit of the manual number will be increased by
one.
•ThisServiceManualcontainsinformationregarding periodic maintenance to the emission control sys-
tem. Please read this material carefully.
•Designsandspecificationsaresubject to change without notice.
EAS30001
IMPORTANT MANUAL INFORMATION
Particularly important information is distinguished in this manual by the following notations.
EAS20002
This is the safety alert symbol. It is used to alert you to potential personal
injury hazards. Obey all safety messages that follow this symbol to avoid
possible injury or death.
A WARNING indicates a hazardous situation which, if not avoided, could
result in death or serious injury.
A NOTICE indicates special precautions that must be taken to avoid
damage to the vehicle or other property.
A TIP provides key information to make procedures easier or clearer.
YZF690/YZF690-U
SERVICE MANUAL
©2022 by Yamaha Motor Co., Ltd.
First edition, August 2021
All rights reserved.
Any reproduction or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd.
is expressly prohibited.
WARNING
NOTICE
TIP

EAS20004
HOW TO USE THIS MANUAL
This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive ex-
planations of all installation, removal, disassembly, assembly, repair and check procedures are laid out
with the individual steps in sequential order.
•Themanualisdividedintochaptersandeachchapterisdividedintosections.Thecurrentsectiontitle
“1” is shown at the top of each page.
•Sub-sectiontitles“2”appearinsmallerprintthanthesectiontitle.
•Tohelpidentifypartsandclarifyproceduresteps,there are exploded diagrams “3” at the start of each
removal and disassembly section.
•Numbers“4”aregivenintheorderofthejobsintheexplodeddiagram.Anumberindicatesadisas-
sembly step.
•Symbols“5”indicatepartstobelubricatedorreplaced.
Refer to “SYMBOLS”.
•Ajobinstructionchart“6”accompaniestheexploded diagram, providing the order of jobs, names of
parts, notes in jobs, etc. This step explains removal and disassembly procedure only. For installation
and assembly procedure, reverse the steps.
•Jobs“7”requiringmoreinformation(suchasspecialtoolsandtechnicaldata)aredescribedsequen-
tially.
1
7
3
5
4
6
2
G088877

EAS20005
SYMBOLS
The following symbols are used in this manual for easier understanding.
TIP
The following symbols are not relevant to every vehicle.
SYMBOL DEFINITION SYMBOL DEFINITION
Serviceable with engine mounted Gear oil
Filling fluid Molybdenum disulfide oil
Lubricant Brake fluid
Special tool Wheel bearing grease
Tightening torque Lithium-soap-based grease
Wear limit, clearance Molybdenum disulfide grease
Engine speed Silicone grease
Electrical data Apply locking agent (LOCTITE®).
Engine oil Replace the part with a new one.
G
M
BF
B
T
R
.
.
LS
M
S
LT
E
New

2
3
9
1
4
5
8
6
7
GENERAL INFORMATION
SPECIFICATIONS
PERIODIC CHECKS AND
ADJUSTMENTS
CHASSIS
ENGINE
COOLING SYSTEM
FUEL SYSTEM
ELECTRICAL SYSTEM
SELF DIAGNOSTIC
TABLE OF CONTENTS

1
GENERAL INFORMATION
IDENTIFICATION ............................................................................................1-1
VEHICLE IDENTIFICATION NUMBER .....................................................1-1
MODEL LABEL..........................................................................................1-1
FEATURES......................................................................................................1-2
MULTI-FUNCTION METER UNIT .............................................................1-2
SPECIAL TOOLS ............................................................................................1-7

1-1
IDENTIFICATION
EAS20007
IDENTIFICATION
EAS30002
VEHICLE IDENTIFICATION NUMBER
The vehicle identification number “1” is stamped
into the right side of the steering head pipe.
EAS30003
MODEL LABEL
The model label “1” is affixed to the frame under
the passenger seat. This information will be
needed to order spare parts.
11
11
1
1
1
1

1-2
FEATURES
EAS20008
FEATURES
EAS30982
MULTI-FUNCTION METER UNIT
The multi-function meter unit is also equipped
with a display brightness and shift timing indica-
tor light settings mode.
WARNING
EWA12423
Be sure to stop the vehicle before making
any setting changes to the multi-function
meter unit. Changing settings while riding
can distract the operator and increase the
risk of an accident.
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The multi-function meter is controlled using the
“SEL/RES” switch.
Switching the display units
The display units can be switched between kilo-
meters and miles. To switch the display units,
set the multi-function display to the odometer or
a tripmeter, and then hold the “SEL” switch until
the display units change.
Speedometer
The speedometer shows the vehicle’s traveling
speed.
Tachometer
The tachometer allows the rider to monitor the
engine speed and keep it within the ideal power
range.
NOTICE
ECA19660
Do not operate the engine in the tachometer
red zone.
Fuel meter
1. Transmission gear display
2. Speedometer
3. Tachometer
4. Fuel meter
5. Clock
6. Multi-function display
7. Quick shift indicator “QS” (if equipped)
1. “SEL/RES” switch
1 2 3 4
5
6
7
1
1
1
1. Tachometer
2. Tachometer red zone
Red zone
10000 r/min and above
1. Fuel meter
12
1

1-3
FEATURES
The fuel meter indicates the amount of fuel in the
fuel tank. The display segments of the fuel meter
disappear from “F” (full) towards “E” (empty) as
the fuel level decreases. When approximately
2.5 L (0.66 US gal, 0.55 Imp.gal) of fuel remains,
the last segment starts flashing. Refuel as soon
as possible.
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If a problem is detected in the electrical circuit,
the fuel level segments will flash repeatedly. Re-
fer to “SIGNALING SYSTEM” on page 8-21.
Clock
The clock uses a 12-hour time system.
To set the clock
1. Turn the vehicle off.
2. While holding the “RES” switch, turn the vehi-
cle on. Continue holding the “RES” switch un-
til the hour digits start flashing.
3. Use the “SEL” switch to set the hours.
4. Push the “RES” switch and the minute digits
start flashing.
5. Use the “SEL” switch to set the minutes.
6. Push the “RES” switch to confirm the setting.
Transmission gear display
This display shows the selected gear. The neu-
tral position is indicated by “–” and by the neutral
indicator light.
Multi-function display
The multi-function display is equipped with the
following:
•anodometer(ODO)
•twotripmeters(TRIP1andTRIP2)
•afuelreservetripmeter(TRIPF)
•aninstantaneousfuelconsumptiondisplay
(km/L, L/100 km, or MPG)
•anaveragefuelconsumptiondisplay(AVE_
_._ km/L, AVE_ _._ L/100 km, or AVE_ _ _._
MPG)
•acoolanttemperaturedisplay(__°C)
•anairtemperaturedisplay(Air__°C)
Push the “SEL” switch to change the display in
the following order:
ODO →TRIP 1 →TRIP 2 →TRIP F →km/L or
L/100 km or MPG →AVE_ _._ km/L or AVE_ _._
L/100 km or AVE_ _._ MPG →_ _ °C →Air_ _
°C →ODO
TIP
•Thefuelreservetripmeterappearsonlywhen
you are low on fuel.
•Usethe“RES”switchtochangethedisplayin
the reverse order.
Odometer
The odometer shows the total distance traveled
by the vehicle.
TIP
The odometer will lock at 999999 and cannot be
reset.
Tripmeters
The tripmeters show the distance traveled since
they were last reset.
To reset a tripmeter, change the display to the
tripmeter you want to reset, and then hold the
“RES” switch until it is reset.
1. Clock
1. Transmission gear display
1
1
1. Multi-function display
1

1-4
FEATURES
TIP
The tripmeters will reset and continue counting
after 9999.9 is reached.
Fuel reserve tripmeter
If the last segment of the fuel meter starts flash-
ing, the display automatically changes to the fuel
reserve tripmeter “TRIP F” and starts counting
the distance traveled from that point.
To reset the fuel reserve tripmeter, change the
display to the fuel reserve tripmeter, and then
hold the “RES” switch until it is reset.
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If you do not reset the fuel reserve tripmeter
manually, it will reset automatically and disap-
pear from the display after refueling and travel-
ing 5 km (3 mi).
Instantaneous fuel consumption display
This display shows the fuel consumption under
the current riding conditions. It can be set to ei-
ther “km/L” or “L/100 km”, or “MPG” when using
miles. To switch the fuel consumption measure-
ment units, hold the “SEL” switch until the mea-
surement units change.
•“km/L”:thedistancethatcanbetraveledon1.0
L of fuel.
•“L/100km”:theamountoffuelnecessaryto
travel 100 km.
•“MPG”:thedistancethatcanbetraveledon
1.0 Imp.gal of fuel.
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When traveling under 10 km/h (6 mi/h), “– –.–” is
displayed.
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The instantaneous fuel consumption function
should be used for general reference only. Do
not use this figure to estimate the distance that
can be traveled on the current tank of fuel.
Average fuel consumption display
This display shows the average fuel consump-
tion since it was last reset. The average fuel con-
sumption display can be set to either “AVE_ _._
km/L” or “AVE_ _._ L/100 km”, or “AVE_ _._
MPG” when using miles. To switch the fuel con-
sumption measurement units, hold the “SEL”
switch until the measurement units change.
•“AVE__._km/L”:theaveragedistancethat
can be traveled on 1.0 L of fuel.
•“AVE__._L/100km”:theaverageamountof
fuel necessary to travel 100 km.
•“AVE__._MPG”:theaveragedistancethat
can be traveled on 1.0 Imp.gal of fuel.
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•Toresetthedisplay,changethedisplaytothe
average fuel consumption display, and hold
the “RES” switch until it is reset.
•Afterresetting,“––.–”isshownuntilthevehicle
has traveled some distance.
Coolant temperature display
1. Instantaneous fuel consumption display
1
1. Average fuel consumption display
1. Coolant temperature display
1
1

1-5
FEATURES
This display shows the coolant temperature from
40 °C to 116 °C in 1 °C increments.
If the message “HI” flashes, stop the vehicle,
then stop the engine, and let it cool.
TIP
•Whenthecoolanttemperatureisbelow40°C,
“Lo” will be displayed.
•Thecoolanttemperaturevarieswithchanges
in the weather and engine load.
Air temperature display
This display shows the air temperature from –9
°C to 50 °C in 1 °C increments. The temperature
displayed may vary from the actual ambient tem-
perature.
TIP
When the temperature is below –9 °C, “_ _” will
be displayed.
Display brightness and shift timing indicator
light settings mode
The following settings can be adjusted in order:
•Displaybrightness
•ShifttimingindicatorlightON/FLASH/OFF
•ShifttimingindicatorlightONr/min
•ShifttimingindicatorlightOFFr/min
•Shifttimingindicatorlightbrightness
To access the settings mode
1. Turn the vehicle off.
2. Hold the “SEL” switch, turn the vehicle on and
continue holding the “SEL” switch until the
display changes to the display brightness
control mode.
3. Use the “RES” switch to change the setting
values.
4. Push the “SEL” switch to confirm the selected
setting value and cycle to the next setting in
the order listed above.
TIP
The settings mode will exit after all settings are
confirmed.
Display brightness
An brightness level indicator bar will appear at
the bottom of the display. Use the “RES” switch
to select the desired brightness level and push
the “SEL” to confirm it.
Shift timing indicator light
The shift timing indicator light has 3 settings:
•ONsetting:theshifttimingindicatorlightwill
come on when the set engine speed is
reached. When this setting is selected, the in-
dicator light will come on and stay on until the
next setting is selected using the “RES” switch
or confirmed with the “SEL” switch.
•FLASHsetting:theshifttimingindicatorlight
will flash when the set engine speed is
reached. When this setting is selected, the shift
timing indicator light will flash 4 times per sec-
ond until the next setting is selected using the
“RES” switch or confirmed with the “SEL”
switch.
•OFFsetting:theshifttimingindicatorlightis
deactivated. When this setting is selected, the
shift timing indicator light will flash once every 2
seconds until the next setting is selected using
the “RES” switch or confirmed with the “SEL”
switch.
Shift timing indicator light ON r/min
The shift timing indicator light can be set be-
tween 6000 r/min and 12000 r/min in increments
of 200 r/min. While changing this setting, the
shift timing indicator light will come on and stay
on and the selected increment will be displayed
on the tachometer. Use the “RES” switch to se-
lect the desired engine speed for activating the
shift timing indicator light.
1. Air temperature display
1
1. Display brightness
1

1-6
FEATURES
Shift timing indicator light OFF r/min
The shift timing indicator light can be set be-
tween 6000 r/min and 12000 r/min in increments
of 200 r/min. While changing this setting, the
shift timing indicator light will flash and the se-
lected increment will be displayed on the ta-
chometer. Use the “RES” switch to select the
desired engine speed for deactivating the shift
timing indicator light.
TIP
Be sure to set the OFF r/min to a higher engine
speed than the ON r/min setting otherwise the
shift timing indicator light will not come on while
riding.
Shift timing indicator light brightness
The shift timing indicator light will come on and
stay on until the setting is confirmed. The bright-
ness level of the light will change as the level is
adjusted. Use the “RES” switch to select the de-
sired brightness level and push the “SEL” to con-
firm it.

1-7
SPECIAL TOOLS
EAS20012
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. Special tools, part numbers or both may differ depending on the country.
When placing an order, refer to the list provided below to avoid any mistakes.
TIP
•ForU.S.A.andCanada,usepartnumberstarting with “YM-”, “YU-”, or “ACC-”.
•Forothers,usepartnumbersstartingwith“90890-”.
Tool name/Tool No. Illustration Reference
pages
Yamaha diagnostic tool USB
90890-03267
3-4, 3-8, 4-67,
4-68, 7-15,
7-15, 7-15,
8-39, 9-3, 9-29,
9-30
Yamaha diagnostic tool (A/I)
90890-03264
3-4, 3-8, 4-67,
4-68, 7-15,
7-15, 7-15,
8-39, 9-3, 9-29,
9-30
Thickness gauge
90890-03268
Feeler gauge set
YU-26900-9
3-6, 4-27, 4-37,
5-57
Valve lapper (ø14)
90890-04101
Valve lapper (ø14)
YM-A8998
3-7
Vacuum gauge
90890-03094
Vacuummate
YU-44456
3-9
90890-04101
YM-A8998
YU-44456

1-8
SPECIAL TOOLS
Carburetor angle driver 2
90890-03173
3-9
Steering nut wrench
90890-01403
Exhaust flange nut wrench
YU-A9472
3-19, 4-88
Oil filter wrench
90890-01426
Oil filter wrench
YU-38411
3-24
Pressure gauge
90890-03153
Pressure gauge
YU-03153
3-25, 7-16, 7-17
Oil pressure adapter H
90890-03139
3-25
Fork spring compressor
90890-01441
Fork spring compressor
YM-01441
4-78, 4-83
Rod holder
90890-01434
Damper rod holder double ended
YM-01434
4-78, 4-83
Damper rod holder (ø27)
90890-01582
Damper rod holder
YM-01582
4-79, 4-80
Fork seal driver
90890-01442
Adjustable fork seal driver (36–46 mm)
YM-01442
4-81, 4-81, 4-82
Tool name/Tool No. Illustration Reference
pages