1999 YAMAHA YZF-R7 Owners Manual

7 - 63
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

7 - 64
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

7 - 65
CHAS
c. Install the fork spring, spacer, spring
seat and nut.
NOTE:
Finger tighten the nut onto the winding
at the damper rod end.
d. Install the rod puller and adapter onto
the damper rod.
e. Press down on the spacer with the
fork spring compressor 9.
f. Pull up the rod puller and install the
rod holder 0 between the nut 4 and
the spring seat.
NOTE:
Use the side of the rod holder that is
marked “A”.
g. Remove the rod puller and adapter.
h. Install the damper adjusting rod,
washer, straight key and cap bolt, and
then finger tighten the cap bolt.
NOTE:
• Make sure that the spring preload
adjusting bolt at the top of cap bolt is
fully, but lightly tightened.
• Insert the cap bolt fully into the
damper rod.
i. Hold the cap bolt and tighten the nut.
j. Remove the rod holder and fork
spring compressor.
WARNINGWARNING
• The fork spring is compressed.
• Always use a new cap bolt O-ring.
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
Rod puller
90890-01437
Adapter
90890-01436
Fork spring compressor
90890-01441
Rod holder
90890-01434
T R..
Nut
25 Nm (2.5 m • kg, 18 ft • lb)
9
0
4
FRONT FORK

7 - 66
CHAS
17.Install:
• outer tube
(onto the cap bolt)
NOTE:
Temporarily tighten the cap bolt.
EB703710
INSTALLING THE FRONT FORK LEGS
The following procedure applies to both of
the front fork legs.
1. Install:
• front fork leg
Temporarily tighten the upper and
lower bracket pinch bolts.
NOTE:
Align the top of the upper bracket with
fourth groove below the cap bolt.
2. Tighten:
• lower bracket pinch bolt 1, 2, 3
NOTE:
Tighten the lower bracket pinch bolts 1,
2 and 3 in the given order and in two
stages. Finally, tighten the pinch bolt 1
once more.
• handlebar pinch bolt
• cap bolt
• upper bracket pinch bolt
WARNINGWARNING
Make sure that the brake hoses are
routed properly.
3. Adjust:
• spring preload
• rebound damping
• compression damping
Refer to “ADJUSTING THE FRONT
FORK LEGS” in chapter 3.
1
1
2

2

3

3

T R..11 Nm (1.1 m · kg, 8.0 ft · lb)
T R..13 Nm (1.3 m · kg, 9.4 ft · lb)
T R..25 Nm (2.5 m · kg, 18 ft · lb)
T R..26 Nm (2.6 m · kg, 19 ft · lb)
FRONT FORK

7 - 67
CHAS
EB704001
HANDLEBARS
T R..26 Nm (2.6 m • kg, 19 ft • Ib)
T R..4 Nm (0.4 m • kg, 2.9 ft • Ib)
T R..13 Nm (1.3 m • kg, 9.4 ft • Ib)
T R..4 Nm (0.4 m • kg, 2.9 ft • Ib)
T R..4 Nm (0.4 m • kg, 2.9 ft • Ib)
T R..115 Nm (11.5 m • kg, 85 ft • Ib)
LS
LS
1
2
7 10 8 11 13
12 17 16 16 18
17
19
2015
14
9 2
563 4
T R..13 Nm (1.3 m • kg, 9.4 ft • Ib)
15
Order Job/Part Q’ty Remarks
Removing the handlebarsRemove the parts in the order listed.
1 Clutch switch coupler 1 Disconnect.
2 Left handlebar switch 1
3 Clutch master cylinder holder 1
4 Clutch master cylinder 1
5 Left grip end 1
6 Handlebar grip 1
7 Right grip end 1
8 Throttle cable housing 1
9 Throttle cable 2
10 Throttle grip 1
HANDLEBARS

7 - 68
CHAS
T R..26 Nm (2.6 m • kg, 19 ft • Ib)
T R..4 Nm (0.4 m • kg, 2.9 ft • Ib)
T R..13 Nm (1.3 m • kg, 9.4 ft • Ib)
T R..4 Nm (0.4 m • kg, 2.9 ft • Ib)
T R..4 Nm (0.4 m • kg, 2.9 ft • Ib)
T R..115 Nm (11.5 m • kg, 85 ft • Ib)
LS
LS
1
2
7 10 8 11 13
12 17 16 16 18
17
19
2015
14
9 2
563 4
T R..13 Nm (1.3 m • kg, 9.4 ft • Ib)
15
Order Job/Part Q’ty Remarks
11 Front brake switch connector 2 Disconnect.
12 Right handlebar switch 1
13 Brake master cylinder holder 1
14 Brake master cylinder 1
15 Handlebar pinch bolt 4
16 Upper bracket bolt 2
17 Upper bracket pinch bolt 2
18 Steering stem nut 1
19 Upper bracket 1
20 Left handlebar 1
21 Right handlebar 1
For installation, reverse the removal
procedure.
HANDLEBARS

7 - 69
CHAS
EB704101
REMOVING THE HANDLEBARS
1. Stand the motorcycle on a level surface.
WARNINGWARNING
Securely support the motorcycle so that
there is no danger of it falling over.
2. Remove:
• handlebar grip
NOTE:
Blow compressed air between the left
handlebar and the handlebar grip, and
gradually push the grip off the handle-
bar.
EB704401
CHECKING THE HANDLEBARS
1. Check:
• left handlebar
• right handlebar
Bends/cracks/damage ® Replace.
WARNINGWARNING
Do not attempt to straighten bent han-
dlebars as this may dangerously
weaken them.
EB704704
INSTALLING THE HANDLEBARS
1. Install:
• brake master cylinder holder 1
ACHTUNG:CAUTION:
• Install the brake master cylinder
holder with the “UP” mark facing up.
• First, tighten the upper bolt, then the
lower bolt.
NOTE:
• Align the mating surfaces of the brake
master cylinder holder with the punch
mark a in the right handlebar.
• There should be 2 mm of clearance
between the right handlebar switch
and the brake master cylinder holder.
UP UP
UP
a
a
1
1

T R..13 Nm (1.3 m · kg, 9.4 ft · lb)
HANDLEBARS

7 - 70
CHAS
2. Install:
• right handlebar switch 1
NOTE:
Align the projection a on the right han-
dlebar switch with the hole b in the
right handlebar.
1
1

a ab
b
3. Install:
• throttle grip 1
• throttle cable housing 2
• throttle cables
NOTE:
Align the projection a on the throttle
cable housing with the hole b in the
right handlebar.
aa
bb
112
2

4. Install:
• clutch master cylinder holder 1
ACHTUNG:CAUTION:
• Install the clutch master cylinder
holder with the “UP” mark facing up.
• First tighten the upper bolt, then the
lower bolt.
NOTE:
Align the slit in the clutch master cylin-
der holder with the punch mark a in the
left handlebar.
U
P UP U
P
1
1

a a
5. Install:
• left handlebar switch 1
NOTE:
Align the projection a on the left han-
dlebar switch with the hole b in the left
handlebar.
1
1
a
a
bb
HANDLEBARS