1999 YAMAHA YZF-R7 torque

4 - 46
ENGCLUTCH
EB405703
INSTALLING THE CLUTCH
1. Install:
• clutch housing
NOTE:
• Make sure that the slots a in the
clutch housing align with the tabs b
on the oil/water pump assembly drive
sprocket.
• Make sure that the primary driven gear
teeth and primary drive gear teeth
mesh correctly.
• Make sure that the starter clutch gear
teeth and starter clutch idle gear teeth
mesh correctly.
2. Install:
• back torque limiter inner boss 1
• back torque limiter bearing 2
• back torque limiter outer boss 3
ACHTUNG:CAUTION:
Be sure that the back torque limiter
bearing is installed facing in the correct
direction as shown.
3. Install:
• lock washer
• clutch boss nut 1
NOTE:
While holding the clutch boss 2 with
the clutch holding tool 3, tighten the
clutch boss nut.
Clutch holding tool
90890-04086
New
T R..70 Nm (7.0 m · kg, 50 ft · lb)

4 - 72
ENGCONNECTING RODS AND PISTONS
NOTE:
Apply only a thin even layer of
MOLYKOTE‚ “G-n” paste, otherwise the
correct tightening torque cannot be
achieved.
6. Lubricate:
• crankshaft pins
• big end bearings
• connecting rod big end inner surface
(with the recommended lubricant)
Recommended lubricant
Engine oil
7. Install:
• big end bearings
• connecting rod assembly
(into the cylinder and onto the crank-
shaft pin)
• connecting rod cap
(onto the connecting rod)
NOTE:
• Align the projections on the big end
bearings with the notches in the con-
necting rods and connecting rod caps.
• Be sure to reinstall each big end bear-
ing in its original place.
• While compressing the piston rings
with piston ring compressor 1, install
the connecting rod assembly into the
cylinder with the other hand.
• Make sure that the “Y” marks a on the
connecting rods face towards the left
side of the crankshaft.
• Make sure that the characters b on
both the connecting rod and connect-
ing rod cap are aligned.
8. Align:
• bolt heads
(with the connecting rods)
Piston ring compressor:
90890-05158
1

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ENGCONNECTING RODS AND PISTONS
9. Tighten:
• connecting rod nuts
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• Tighten the connecting rod nuts in the
following way.
NOTE:
• How much the connecting rod nut is
tightened depends on how much the
connecting rod bolt stretches.
• Use a general micrometer 1 to mea-
sure the connecting rod bolts.
a. Before tightening the connecting rod
nut, measure the length of the con-
necting rod bolt with an accuracy of
three decimal places.
b. First tighten the connecting rod nut to
20 Nm (2.0 m • kg, 14 ft • lb), then up
to 40 Nm (4.0 m • kg, 29 ft • lb).
c. Measure the length of the connecting
rod bolt after tightening the connect-
ing rod nut and then calculate how
much the bolt has stretched.
d. Further tighten the connecting rod
nut until the connecting rod bolt has
stretched by between 0.170 and
0.175 mm.
ACHTUNG:CAUTION:
If the connecting rod nut cannot eventu-
ally be tightened to about 50 Nm (5.0 m
• kg, 36 ft • lb), too much MOLYKOTE
®‚
“G-n” paste may have been applied.
Loosen the connecting rod nut and
check the loosening torque. If the loos-
ening torque is less than 40 Nm (4.0 m •
kg, 29 ft • lb), too much MOLYKOTE
®‚
“G-n” paste was applied. In that case,
replace the connecting rod bolt with a
new one and apply a thin uniform layer
of MOLYKOTE
®‚ “G-n” paste to the
threads of the connecting rod bolt, the
contact area between the connecting
rod and the connecting rod bolt, and the
seat of the connnecting rod nut. Then,
tighten the connecting rod nut as
explained above.
WARNINGWARNING
Always replace the connecting rod bolt
with a new one if loosening the con-
necting rod nut after it was tightened.
Never use a connecting rod bolt more
than once.
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0.17 0
1

7 - 82
CHAS
EB707100
NOTE:
Before removing the drive sprocket,
drive chain, and rear wheel, measure the
drive chain slack and the length of a ten-
link section of the drive chain.
EB707111
REMOVING THE SWINGARM
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. Measure:
• swingarm side play
• swingarm vertical movement
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a. Measure the tightening torque of the
pivot shaft nut.
b. Measure the swingarm side play
by moving the swingarm from side to
side.
c. If the swingarm side play is out of
specification, check the spacers, bear-
ings, washers, and dust covers.
d. Check the swingarm vertical move-
ment
õ by moving the swingarm up
and down.
If swingarm vertical movement is not
smooth or if there is binding, check the
spacers, bearings, washers, and dust
covers.
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..
Pivot shaft nut
125 Nm (12.5 m • kg, 90 ft • lb)
Swingarm side play (at the
end of the swingarm)
1.0 mm (0.04 in)
SWINGARM AND DRIVE CHAIN