1999 YAMAHA YZF-R7 Owners Manual

7 - 55
CHAS
EB703001
FRONT FORK
T R..7 Nm (0.7 m • kg, 5.1 ft • Ib)
T R..11 Nm (1.1 m • kg, 8.0 ft • Ib)
T R..13 Nm (1.3 m • kg, 9.4 ft • Ib)
T R..26 Nm (2.6 m • kg, 19 ft • Ib)
T R..25 Nm (2.5 m • kg, 18 ft • Ib)
123
54
6
Order Job/Part Q’ty Remarks
Removing the front fork legsRemove the parts in the order listed.
The following procedure applies to
both of the front fork legs.
Bottom cowling and front cowling Refer to “COWLINGS” in chapter 3.
Front wheel Refer to “FRONT WHEEL AND BRAKE
DISCS”.
1 Front fender 1
2 Upper bracket pinch bolt 1 Loosen.
3 Cap bolt 1 Loosen.
4 Handlebar pinch bolt 2
5 Lower bracket pinch bolt 3
6 Front fork leg 1
For installation, reverse the removal
procedure.
FRONT FORK

7 - 56
CHAS
EB703002
Order Job/Part Q’ty Remarks
Disassembling the front fork legsRemove the parts in the order listed.
The following procedure applies to
both of the front fork legs.
1 Cap bolt/O-ring 1/1
2 Straight key 1
3 Washer 1
4 Damper adjusting rod 1
5 Nut 1
6 Spring seat 1
7Spacer 1
8Fork spring 1
9 Outer tube 1
0Dust seal 1
A Oil seal clip 1
B Oil seal 1
CWasher 1
FRONT FORK

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CHAS
Order Job/Part Q’ty Remarks
D Damper rod assembly 1
E Inner tube 1
For assembly, reverse the disassembly
procedure.
FRONT FORK

7 - 58
CHAS
EB703100
REMOVING THE FRONT FORK LEGS
The following procedure applies to both of
the front fork legs.
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 front wheel is elevated.
2. Adjust:
• spring preload
NOTE:
Turn the adjusting bolt 1 in fully so that
it sits lightly. Refer to “ADJUSTING THE
FRONT FORK LEGS” in chapter 3.
1
1

3. Loosen:
• upper bracket pinch bolt 1
• cap bolt 2
(with the front fork cap bolt wrench)
• handlebar pinch bolts
• lower bracket pinch bolts
WARNINGWARNING
Before loosening the upper and lower
bracket pinch bolts and handlebar pinch
bolt, support the front fork leg.
4. Remove:
• front fork leg
Front fork cap bolt wrench:
90890-01472
1
1
2

2

EB703113
DISASSEMBLING THE FRONT FORK LEGS
The following procedure applies to both of
the front fork legs.
1. Remove:
• cap bolt 1
(from the damper rod assembly)
• straight key
• washer
• damper adjusting rod
4
51
2
3
FRONT FORK

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CHAS
• nut 2
• spring seat 3
• spacer
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. Press down on the spacer with the
fork spring compressor 4.
b. Install the rod holder 5 between the
nut 2 and the spring seat 3.
NOTE:
Use the side of the rod holder that is
marked “A”.
c. Loosen the nut.
d. Remove the cap bolt, straight key,
washer and damper adjusting rod.
e. Remove the rod holder and fork
spring compressor.
WARNINGWARNING
The fork spring is compressed.
f. Remove the nut, spring seat and
spacer.
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
Fork spring compressor
90890-01441
Rod holder
90890-01434
2. Drain:
• fork oil
NOTE:
Stroke the damper rod 1 several times
while draining the fork oil.
3. Remove:
• outer tube
(from inner tube)
4. Remove:
• dust seal
• oil seal clip 1
• oil seal
• washer
(with a flat-head screwdriver)
FRONT FORK

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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