1999 YAMAHA YZF-R7 warning

7 - 59
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.
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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

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

7 - 61
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
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.
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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

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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

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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

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CHAS
6. Install:
• handlebar grip
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. Apply a thin coat of rubber adhesive
onto the end of the left handlebar.
b. Slide the handlebar grip over the end
of the left handlebar.
c. Wipe off any excess rubber adhesive
with a clean rag.
WARNINGWARNING
Do not touch the handlebar grip until
the rubber adhesive has fully dried.
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7. Adjust:
• throttle cable free play
Refer to “ADJUSTING THE THROTTLE
CABLE FREE PLAY” in chapter 3.
Throttle cable free play (at the
flange of the throttle grip)
3 ~ 5 mm (0.12 ~ 0.20 in)
HANDLEBARS

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CHAS
EB705100
REMOVING THE LOWER BRACKET
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:
• lower ring nut 1
(with the special tool 2)
WARNINGWARNING
Securely support the lower bracket so
that there is no danger of it falling.
Ring nut wrench
90890-01403
EB705401
CHECKING THE STEERING HEAD
1. Wash:
• bearing balls
• bearing races
Recommended cleaning solvent
Kerosine
2. Check:
• bearing balls 1
• bearing races 2
Damage/pitting ® Replace.
3. Check:
• upper bracket
• lower bracket
(along with the steering stem)
Bends/cracks/damage ® Replace.
STEERING HEAD