1999 YAMAHA YZF-R7 wheel bolts

2 - 21
SPEC
CHASSIS TIGHTENING TORQUES
HINWEIS:NOTE:
1.First, tighten the ring nut to approximately 18 Nm (1.8 m • kg, 13 ft • lb) with a torque
wrench, then loosen the ring nut completely.
2.Retighten the ring nut to specification.Item Thread sizeTightening torque
Remarks
Nm m·kgf ft·lb
Upper bracket pinch bolts M8 26 2.6 19
Steering stem nut M28 115 11.5 85
Handlebar pinch bolts M6 13 1.3 9.4
Lower ring nut M30 9 0.9 6.5 See NOTE.
Lower bracket pinch bolts M6 11 1.1 8.0
Front brake hose union bolts M10 30 3.0 22
Front brake master cylinder M6 13 1.3 9.4
Engine mounting
Spacer bolts M16 18 1.8 13
Left front mounting bolts M10 40 4.0 29
Right front mounting bolts M10 40 4.0 29
Rear mounting bolts M10 55 5.5 40
Pinch bolts M8 17 1.7 12
Exhaust pipe bracket M8 24 2.4 17
Pivot shaft nut M18 125 12.5 90
Connecting arms M10 40 4.0 29
Relay arm and connecting arms M10 40 4.0 29
Relay arm M10 40 4.0 29
Rear shock absorber and relay arm M10 40 4.0 29
Rear shock absorber assembly M10 40 4.0 29
Fuel pump and fuel tank M5 4 0.4 2.9
Coolant reservoir and radiator M6 5 0.5 3.6
Rider footrest bracket M8 28 2.8 20
Rear master cylinder M8 23 2.3 17
Rear brake hose union bolts M10 30 3.0 22
Sidestand bracket M8 26 2.6 19
Front wheel axle M20 79 7.9 57
Rear wheel axle M24 150 15.0 110
Rear wheel axle nut M24 45 4.5 32
Front brake caliper and front fork M10 40 4.0 29
Rear brake caliper and bracket M10 40 4.0 29
Brake disc and wheel M6 18 1.8 13
Rear wheel sprocket and rear wheel
drive hubM10 69 6.9 50
Brake caliper and bleed screw M8 6 0.6 4.3
Pinch bolt (front wheel axle) M8 23 2.3 17
TIGHTENING TORQUES

2 - 22
SPEC
EB202000
LUBRICATION POINTS AND LUBRICANT TYPES
ENGINE LUBRICATION POINTS AND LUBRICANT TYPES
Lubrication point Lubricant
Oil seal lips
LS
O-ringsLS
BearingsE
Crankshaft pinsE
Piston surfacesE
Piston pinsE
Connecting rod bolts and nuts MOLYKOTE® G-n paste
Crankshaft journals
E
Camshaft lobesM
Camshaft journalsM
Valve stems (intake and exhaust)M
Valve stem ends (intake and exhaust)E
Water pump impeller shaftE
Oil pump rotors (inner and outer)E
Oil pump housing E
Oil strainer E
Starter clutch idle gear inner surfaceE
Starter clutch assemblyE
Primary driven gearE
Transmission gears (wheel and pinion)M
Main axle and drive axleM
Shift drumE
Shift forks and shift fork guide barsE
Shift shaft E
Shift shaft bossLS
Cylinder head cover mating surfaceYamaha bond
No. 1215
Cylinder head coverYamaha bond
No. 1215
Crankcase mating surfaceYamaha bond
No. 1215
Clutch cover (crankcase mating surface)Yamaha bond
No. 1215
Generator rotor cover (crankcase mating surface)Yamaha bond
No. 1215
Pickup coil rotor cover (crankcase mating surface)Yamaha bond
No. 1215
LUBRICATION POINTS AND LUBRICANT TYPES

3 - 42
CHK
ADJ
ADJUSTING THE DRIVE CHAIN SLACK
2. Rotate the rear wheel several times and
check the drive chain to locate its tight-
est point.
3. Measure:
• drive chain slack a
Out of specification ® Adjust.
Drive chain slack
40 ~ 50 mm (1.57 ~ 1.97 in)
4. Adjust:
• drive chain slack
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. Loosen the wheel axle nut 1 and
wheel axle.
b. Loosen both locknuts 2.
c. Turn both adjusting bolts 3 in direc-
tion a or b until the specified drive
chain slack is obtained.
NOTE:
To maintain the proper wheel align-
ment, adjust both sides evenly.
d. Tighten both locknuts.
e. Tighten the wheel axle and wheel
axle nut to specification.
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
Direction aDrive chain slack is
decreased.
Direction bDrive chain slack is
increased.
T R..
Wheel axle
150 Nm
(15.0 m • kg, 110 ft • lb)
Wheel axle nut
45 Nm (4.5 m • kg, 32 ft • lb)
1
1
2
2

3
3
a a
b b

4 - 11
ENG

CAMSHAFTS
EB401101
REMOVING THE CAMSHAFTS
1. Align:
• TDC mark on the pickup coil rotor
(with the crankcase mating surface)
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. Turn the crankshaft clockwise.
b. When piston #1 is at TDC on the com-
pression stroke, align the TDC
mark
a
on the pickup coil rotor with
the crankcase mating surface
b
.
NOTE:

TDC on the compression stroke can be
found when the camshaft lobes are
turned away from each other.
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
2. Remove:
• float chamber air vent hose holder
• timing chain tensioner
3. Remove:
• timing chain guide (exhaust side)
4. Remove:
• camshaft caps
• dowel pins
ACHTUNG:CAUTION:

To prevent damage to the cylinder
head, camshafts or camshaft caps,
loosen the camshaft cap bolts in stages
and in a crisscross pattern, working
from the outside in.
H H
T
T
a
a
b
b

5. Remove:
• intake camshaft
1

• exhaust camshaft
2
NOTE:
To prevent the timing chain from falling
into the crankcase, fasten it with a
wire 3.
6. Remove:
• camshaft sprockets 1
(with the flywheel puller 2)
Flywheel puller
90890-01080

4 - 33
ENG

GENERATOR
EB410110
REMOVING THE GENERATOR
1. Remove:
• generator rotor cover
1

NOTE:

Loosen each bolt 1/4 of a turn at a time,
in stages and in a crisscross pattern.
After all of the bolts are fully loosened,
remove them.
1
1

2. Remove:
• generator rotor bolt
1

• washer
NOTE:

While holding the generator rotor
2
with the rotor holding tool
3
, loosen the
generator rotor bolt.
Rotor holding tool
90890-01235
3. Remove:
• generator rotor
1
(with the flywheel puller
2
and rotor
holding tool
3
)
Flywheel puller
90890-01080
EB410700
INSTALLING THE GENERATOR
1. Apply:
• sealant
(onto the stator coil assembly lead
grommet)
2. Install:
• generator rotor
• washer
• generator rotor bolt
WARNINGWARNING

Always use a new generator rotor bolt.
ACHTUNG:CAUTION:

• Clean the tapered portion of the crank-
shaft and the generator rotor hub with
lacquer thinner.
• Lubricate the generator rotor bolt
threads with engine oil.
Yamaha bond No. 1215
90890-85505

4 - 53
ENGOIL PAN AND OIL PUMP
EB411100
REMOVING THE OIL PAN
1. Remove:
• oil level switch 1
• oil pan 2
• oil pan gasket
• dowel pins
NOTE:
Loosen each bolt 1/4 of a turn at a time,
in stages and in a crisscross pattern.
After all of the bolts are fully loosened,
remove them.
REMOVING THE OIL PUMP
1. Remove:
• oil/water pump assembly driven
sprocket
Flywheel puller
90890-01080
EB411400
CHECKING THE OIL PUMP
1. Check:
• oil/water pump assembly driven
sprocket 1
• oil pump housing 2
Cracks/damage/wear ® Replace the
defective part(-s).
2. Measure:
• inner rotor-to-outer rotor tip clearance
a
• outer rotor-to-oil pump housing clear-
ance b
Out of specification ® Replace the oil
pump.
1 Inner rotor
2 Outer rotor
3 Oil pump housing
Inner rotor-to-outer rotor tip
clearance
0.09 ~ 0.15 mm
(0.004 ~ 0.006 in)
Outer rotor-to-oil pump hous-
ing clearance
0.03 ~ 0.08 mm
(0.001 ~ 0.003 in)

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)