1999 YAMAHA YZF-R7 brake

3 - 46
CHK
ADJCHECKING AND ADJUSTING THE STEERING HEAD/
CHECKING THE FRONT FORK
d. Hold the spring gauge at a 45˚ angle
from the handlebar, pull the spring
gauge, and record the measurement
when the handlebar starts to turn.
e. Repeat the above procedure on the
opposite handlebar.
f. If the steering head tension is out of
specification (both handlebars should
be within specification), remove the
upper bracket and loosen or tighten
the upper ring nut.
g. Reinstall the upper bracket and mea-
sure the steering head tension again
as described above.
h. Repeat the above procedure until the
steering head tension is within speci-
fication.
i. Grasp the bottom of the front fork
legs and gently rock the front fork.
Looseness or binding ® Adjust the
steering head.
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
Steering head tension
200 ~ 500 g (7.06 ~ 17.65 oz)
EB304141
CHECKING THE FRONT FORK
1. Stand the motorcycle on a level surface.
WARNINGWARNING
Securely support the motorcycle so that
there is no danger of it falling over.
2. Check:
• inner tube 1
Damage/scratches ® Replace.
• dust seal 2
• oil seal
Oil leakage ® Replace.
3. Hold the motorcycle upright and apply
the front brake.
4. Check:
• front fork operation
Push down hard on the handlebars
several times and check if the front
fork rebounds smoothly.
Rough movement ® Repair.
Refer to “FRONT FORK” in chapter 7.

7 - 1
CHAS

FRONT WHEEL AND BRAKE DISCS
EB700002
CHASSIS
FRONT WHEEL AND BRAKE DISCS
Order Job/Part Q’ty Remarks
Removing the front wheel and brake
discs
Remove the parts in the order listed.
1 Brake hose holder (left and right) 2
2 Brake caliper (left and right) 2
3 Wheel axle pinch bolt 4 Loosen.
4 Front wheel axle 1
5 Front wheel 1
6 Collar (left and right) 2
7 Oil seal cover (left and right) 2
8 Brake disc (left and right) 2
For installation, reverse the removal
procedure.
NOTE:
Place the motorcycle on a suitable
stand so that the front wheel is ele-
vated.

7

7 - 2
CHAS

FRONT WHEEL AND BRAKE DISCS
EB700010
Order Job/Part Q’ty Remarks
Disassembling the front wheel
Remove the parts in the order listed.
1
Oil seal (left and right) 2
2
Wheel bearing (left and right) 2
3
Spacer 1
For assembly, reverse the disassembly
procedure.
7

7 - 3
CHAS

FRONT WHEEL AND BRAKE DISCS
EB700102
REMOVING THE FRONT WHEEL
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. Remove:
• left brake caliper
• right brake caliper
NOTE:

Do not squeeze the brake lever when
removing the brake calipers.
3. Elevate:
• front wheel
NOTE:

Place the motorcycle on a suitable stand
so that the front wheel is elevated.
EB700400
CHECKING THE FRONT WHEEL
1. Check:
• wheel axle
Roll the wheel axle on a flat surface.
Bends
®
Replace.
WARNINGWARNING

Do not attempt to straighten a bent
wheel axle.
2. Check:
• tire
• front wheel
Damage/wear
®
Replace.
Refer to “CHECKING THE TIRES” and
“CHECKING THE WHEELS” in chapter 3.

7 - 4
CHAS

FRONT WHEEL AND BRAKE DISCS
3. Measure:
• radial wheel runout
1
• lateral wheel runout
2
Over the specified limits
®
Replace.
4. Check:
• wheel bearings
Front wheel turns roughly or is loose
®
Replace the wheel bearings.
• oil seals
Damage/wear
®
Replace.
Max. radial wheel runout
1.0 mm (0.04 in)
Max. lateral wheel runout
0.5 mm (0.02 in)
5. Replace:
• wheel bearings
• oil seals
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. Clean the outside of the front wheel
hub.
b. Remove the oil seals
1
with a flat-
head screwdriver.
NOTE:

To prevent damaging the wheel, place a
rag
2
between the screwdriver and the
wheel surface.
c. Remove the wheel bearings
3
with a
general bearing puller.
d. Install the new wheel bearings and oil
seals in the reverse order of disas-
sembly.
ACHTUNG:CAUTION:

Do not contact the wheel bearing center
race
4
or balls
5
. Contact should be
made only with the outer race
6
.
NOTE:

• First fully insert the right wheel bear-
ing, then install the spacer and finally
the left wheel bearing.
• Use a socket
7
that matches the diam-
eter of the wheel bearing outer race
and oil seal.
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
New
New

7 - 5
CHAS

FRONT WHEEL AND BRAKE DISCS
EB700416
CHECKING THE BRAKE DISCS
The following procedure applies to both of
the brake discs.
1. Check:
• brake disc
Damage/galling
®
Replace.
2. Measure:
• brake disc deflection
Out of specification
®
Correct the
brake disc deflection or replace the
brake disc.
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. Place the motorcycle on a suitable
stand so that the wheel is elevated.
b. Before measuring the front brake disc
deflection, turn the handlebars to the
left or right to ensure that the front
wheel is stationary.
c. Remove the brake caliper.
d. Hold the dial gauge at a right angle
against the brake disc surface.
e. Measure the deflection 1.5 mm
(0.06 in) below the edge of the brake
disc.
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
Max. brake disc deflection
Front: 0.1 mm (0.004 in)
Rear: 0.1 mm (0.004 in)
3. Measure:
• brake disc thickness
Measure the brake disc thickness at a
few different locations.
Out of specification
®
Replace.
Min. brake disc thickness
Front: 4.5 mm (0.18 in)
Rear: 4.5 mm (0.18 in)
4. Adjust:
• brake disc deflection
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 brake disc.
b. Rotate the brake disc by one bolt
hole.
c. Install the brake disc.
NOTE:

Tighten the brake disc bolts in stages
and in a crisscross pattern.

7 - 6
CHAS

FRONT WHEEL AND BRAKE DISCS
d. Measure the brake disc deflection.
e. If out of specification, repeat the
adjustment steps until the brake disc
deflection is within specification.
f. If the brake disc deflection cannot be
brought within specification, replace
the brake disc.
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..

Brake disc bolt
18 Nm (1.8 m • kg, 13 ft • lb)
LOCTITE
Ò

EB700725
INSTALLING THE FRONT WHEEL
1. Lubricate:
• wheel axle
• oil seal lips
Recommended lubricant
Lithium soap base grease
2. Install:
• brake discs
NOTE:

• Apply locking agent (LOCTITE
Ò

) 648 to
the threads of the brake disc bolts.
• Tighten the brake disc bolts in stages
and in a crisscross pattern.
T R..18 Nm (1.8 m · kg, 13 ft • lb)

3. Tighten:
• wheel axle
1
• wheel axle pinch bolt
2
ACHTUNG:CAUTION:

Before tightening the wheel axle nut,
push down hard on the handlebars sev-
eral times and check if the front fork
rebounds smoothly.
1
1

2
2

T R..79 Nm (7.9 m · kg, 57 ft · lb)
T R..23 Nm (2.3 m · kg, 17 ft · lb)

7 - 7
CHASFRONT WHEEL AND BRAKE DISCS
4. Install:
• brake calipers
WARNINGWARNING
Make sure that the brake hose is routed
properly.
T R..40 Nm (4.0 m · kg, 29 ft · lb)
EB700901
ADJUSTING THE FRONT WHEEL STATIC
BALANCE
NOTE:
• After replacing the tire, wheel or both,
the front wheel static balance should
be adjusted.
• Adjust the front wheel static balance
with the brake discs installed.
1. Remove:
• balancing weight(-s)
2. Find:
• front wheel’s heavy spot
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. Place the front wheel on a suitable
balancing stand.
b. Spin the front wheel.
c. When the front wheel stops, put an
“X
1” mark at the bottom of the wheel.
d. Turn the front wheel 90˚ so that the
“X
1” mark is positioned as shown.
e. Release the front wheel.
f. When the front wheel stops, put an
“X
2” mark at the bottom of the wheel.
g. Repeat steps (a) through (d) several
times until all the marks come to rest
at the same spot.
h. The spot where all the marks come to
rest is the front wheel’s heavy spot
“X”.
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