1999 YAMAHA YZF-R7 oil

7 - 60
CHAS
5. Remove:
• damper rod assembly
(with the damper rod holder 1)
Damper rod holder
90890-01473
EB703401
CHECKING THE FRONT FORK LEGS
The following procedure applies to both of
the front fork legs.
1. Check:
• inner tube 1
• outer tube 2
Bends/damage/scratches ® Replace.
WARNINGWARNING
Do not attempt to straighten a bent
inner tube as this may dangerously
weaken it.
2. Measure:
• spring free length a
Out of specification ® Replace.
Spring free length limit
240 mm (9.45 in)
3. Check:
• damper rod 1
Damage/wear ® Replace.
Obstruction ® Blow out all of the oil
passages with compressed air.
ACHTUNG:CAUTION:
• The front fork leg has a built-in
damper adjusting rod and a very
sophisticated internal construction,
which are particularly sensitive to for-
eign material.
• When disassembling and assembling
the front fork leg, do not allow any for-
eign material to enter the front fork.
FRONT FORK

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CHAS

4. Check:
• cap bolt O-ring
Damage/wear
®
Replace.
EB703702
ASSEMBLING THE FRONT FORK LEGS
The following procedure applies to both of
the front fork legs.
WARNINGWARNING

• Make sure that the oil levels in both
front fork legs are equal.
• Uneven oil levels can result in poor
handling and a loss of stability.
NOTE:

• When assembling the front fork leg, be
sure to replace the following parts:
- inner tube bushing
- outer tube bushing
- oil seal
- dust seal
• Before assembling the front fork leg,
make sure that all of the components
are clean.
1. Install:
• damper rod assembly
1
ACHTUNG:CAUTION:

Allow the damper rod assembly to slide
slowly down the inner tube
2
until it
protrudes from the bottom of the inner
tube. Be careful not to damage the inner
tube.
NOTE:

Be sure that the clip
3
is still correctly
installed.
2. Lubricate:
• inner tube’s outer surface
Recommended lubricant
Yamaha fork and shock oil
M1 or equivalent
FRONT FORK

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CHAS

3. Tighten:
• damper rod assembly
(with the damper rod holder
1
)
4. Install:
• dust seal
1

• oil seal clip
2

• oil seal
3

• washer
4

ACHTUNG:CAUTION:

Make sure that the numbered side of
the oil seal faces up.
NOTE:

• Before installing the oil seal, lubricate
its lips with lithium soap base grease.
• Lubricate the outer surface of the inner
tube with fork oil.
• Before installing the oil seal, cover the
top of the front fork leg with a plastic
bag
5
to protect the oil seal during
installation.
5. Install:
• outer tube
(onto the inner tube)
Damper rod holder
90890-01473
T R..48 Nm (4.8 m · kg, 35 ft · lb)

6. Install:
• washer
• oil seal
1
(with the fork seal driver
2
)
Fork seal driver
90890-01442
7. Install:
• oil seal clip
1
NOTE:

Adjust the oil seal clip so that it fits into
the outer tube’s groove.
FRONT FORK

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CHAS

8. Install:
• dust seal
1
(with the fork seal driver
2
)
9. Install:
• rod puller
1
• adapter
2
(onto the damper rod
3
)
10.Fully compress the front fork leg.
11.Fill:
• front fork leg
(with the specified amount of the rec-
ommended fork oil)
ACHTUNG:CAUTION:

• Be sure to use the recommended fork
oil. Other oils may have an adverse
effect on front fork performance.
• When disassembling and assembling
the front fork leg, do not allow any for-
eign material to enter the front fork.
Rod puller
90890-01437
Adapter
90890-01436
Quantity (each front fork leg)
460 cm
3


(16.2 Imp oz, 15.6 US oz)
Recommended oil
Yamaha fork and shock oil
01 or equivalent
12.After filling the front fork leg, slowly
stroke the damper rod
1
up and down
(at least ten times) to distribute the fork
oil.
NOTE:

Be sure to stroke the damper rod slowly
because the fork oil may spurt out.
FRONT FORK

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CHAS

13.Slowly stroke the outer tube
1
up and
down to distribute the fork oil once
more (1 stroke = about 100 mm, 3.94 in).
NOTE:

Be careful not to stroke the inner tube
over 100 mm as this will cause air to
enter. If the inner tube is stroked more
than 100 mm, repeat steps (12) and (13).
14.Before measuring the fork oil level, wait
ten minutes until the oil has settled and
the air bubbles have dispersed.
NOTE:

Be sure to bleed the front fork leg of any
residual air.
15.Measure:
• front fork leg oil level
a
Out of specification
®
Correct.
Front fork leg oil level (from
the top of the outer tube, with
the outer tube fully down, and
without the spring)
170 mm (6.69 in)
16.Install:
• fork spring
1
• spacer
2
• spring seat
3
• nut
4
• damper adjusting rod
5

• washer
6
• straight key
7
• cap bolt 8
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. Remove the rod puller and adapter.
b. Install the nut.
6
7
8
2
3451
FRONT FORK

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CHAS
EB706000
REAR SHOCK ABSORBER ASSEMBLY
Order Job/Part Q’ty Remarks
Removing the rear shock absorber
assemblyRemove the parts in the order listed.
1 Bolt 1
2 Self-locking nut/bolt 1/1
3 Self-locking nut/bolt 2/2
4 Self-locking nut/bolt 1/1
5 Rear shock absorber assembly 1
6 Self-locking nut/bolt 1/1
7 Connecting arm 2
8 Spacer/oil seal/bearing2/4/2
9 Sidestand 1
10 Self-locking nut/bolt/spacer1/1/1
11 Relay arm 1
12 Spacer/oil seal/bearing3/6/3
For installation, reverse the removal
procedure.
REAR SHOCK ABSORBER ASSEMBLY

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CHAS
EB706204
REMOVING THE REAR SHOCK ABSORBER
ASSEMBLY
1. Stand the motorcycle on a level surface.
WARNINGWARNING
Securely support the motorcycle so that
there is no danger of it falling over.
NOTE:
Place the motorcycle on a suitable stand
so that the rear wheel is elevated.
2. Remove:
• rear shock absorber assembly lower
bolt 1
• connecting arm-to-swingarm bolt 2
NOTE:
While removing the rear shock absorber
assembly lower bolt, hold the swingarm
so that it does not drop down.
2
2
2
2

1

1

3. Remove:
• rear shock absorber assembly upper
bolt 1
• rear shock absorber assembly
NOTE:
Raise the swingarm and then remove
the rear shock absorber assembly from
between the swingarm.
1
1

EB706401
CHECKING THE REAR SHOCK ABSORBER
ASSEMBLY AND GAS CYLINDER
1. Check:
• rear shock absorber rod
Bends/damage ® Replace the rear
shock absorber assembly.
• rear shock absorber
Gas leaks/oil leaks ® Replace the rear
shock absorber assembly.
• spring
Damage/wear ® Replace the rear
shock absorber assembly.
• gas cylinder
Damage/gas leaks ® Replace.
• bushings
Damage/wear ® Replace.
• dust seals
Damage/wear ® Replace.
• bolts
Bends/damage/wear ® Replace.
REAR SHOCK ABSORBER ASSEMBLY

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CHAS
CHECKING THE RELAY ARM AND
CONNECTING ARM
1. Check:
• relay arm 1
• connecting arm 2
Damage/wear ® Replace.
• bearings
• oil seals
Damage/pitting ® Replace.
• spacers
Damage/scratches ® Replace.
1
1
2
2

2

2

EB706701
INSTALLING THE REAR SHOCK ABSORBER
ASSEMBLY
1. Lubricate:
• bearings
• oil seals
• spacers
2. Install:
• relay arm
• connecting arms
• rear shock absorber assembly
NOTE:
When installing the rear shock absorber
assembly, lift up the swingarm.
3. Tighten:
• relay arm-to-frame nut
• relay arm-to-connecting arm nut
• connecting arm-to-swingarm nut
• rear shock absorber assembly upper nut
• rear shock absorber assembly lower nut
Recommended lubricant
Molybdenum disulfide grease
T R..40 Nm (4.0 m · kg, 29 ft · lb)
T R..40 Nm (4.0 m · kg, 29 ft · lb)
T R..40 Nm (4.0 m · kg, 29 ft · lb)
T R..40 Nm (4.0 m · kg, 29 ft · lb)
T R..40 Nm (4.0 m · kg, 29 ft · lb)
REAR SHOCK ABSORBER ASSEMBLY