YAMAHA YZF-R7 1999 Owners Manual

7 - 51
CHAS
EAS00312
Order Job/Part Q’ty Remarks
Disassembling the clutch release
cylinderRemove the parts in the order listed.
1Dust seal 1
2Clutch release cylinder piston 1
3Spring 1
4Oil seal 1
5Bleed screw 1
For assembly, reverse the disassembly
procedure.
HYDRAULIC CLUTCH

7 - 52
CHAS
EAS00313
DISASSEMBLING THE CLUTCH RELEASE
CYLINDER
1. Remove:
• dust seal 1
• clutch release cylinder piston 2
• spring 3
• oil seal 4
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. Blow compressed air into the clutch
hose joint opening a to force out the
piston from the clutch release cylin-
der.
WARNINGWARNING
• Cover the clutch release cylinder with
a rag. Be careful not to get injured
when the piston is expelled from the
clutch release cylinder.
• Never try to pry out the clutch release
cylinder piston.
b. Remove the clutch release cylinder 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
EAS00314
CHECKING THE CLUTCH RELEASE
CYLINDER
1. Check:
• clutch release cylinder body 1
Cracks/damage ® Replace the clutch
release cylinder.
• clutch release cylinder 2
• clutch release cylinder piston 3
Rust/scratches/wear ® Replace the
clutch release cylinder and clutch
release cylinder piston as a set.
1
1

2
2

3
3

HYDRAULIC CLUTCH

7 - 53
CHAS
EAS00315
ASSEMBLING AND INSTALLING THE
CLUTCH RELEASE CYLINDER
WARNINGWARNING
• Before installation, all internal clutch
components must be cleaned and
lubricated with clean or new clutch
fluid.
• Never use solvents on internal clutch
components as they will cause the oil
seal and dust seal to swell and distort.
• Whenever a clutch release cylinder is
disassembled, replace the oil seal and
dust seal.
Recommended clutch fluid
Brake fluid DOT 4
1. Check:
• copper washer 1
• clutch hose 2
• union bolt 3
WARNINGWARNING
Proper clutch hose routing is essential
to insure safe motorcycle operation.
Refer to “CABLE ROUTING”.
ACHTUNG:CAUTION:
When installing the clutch hose onto the
clutch release cylinder, make sure that
the pipe a touches the projection b.
2. Fill:
• clutch fluid reservoir
(with the specified amount of the rec-
ommended clutch fluid)
WARNINGWARNING
• Use only the designated clutch fluid.
Other clutch fluids may cause the rub-
ber seals to deteriorate, causing leak-
age and poor clutch performance.
• Refill with the same type of clutch
fluid that is already in the system.
Mixing clutch fluids may result in a
harmful chemical reaction, leading to
poor clutch performance.Recommended clutch fluid
Brake fluid DOT 4
2
2

3

3

a a
1
1

b b
New
T R..26 Nm (2.6 m · kg, 19 ft · lb)
HYDRAULIC CLUTCH

7 - 54
CHAS
• When refilling, be careful that water
does not enter the reservoir. Water
will significantly lower the boiling
point of the clutch fluid and could
cause vapor lock.
ACHTUNG:CAUTION:
Clutch fluid may damage painted sur-
faces or plastic parts. Therefore, always
clean up any spilt clutch fluid immedi-
ately.
3. Bleed:
• clutch system
Refer to “BLEEDING THE HYDRAULIC
CLUTCH SYSTEM” in chapter 3.
4. Check:
• clutch fluid level
Below the minimum level mark a ®
Add the recommended clutch fluid to
the proper level.
Refer to “CHECKING THE CLUTCH
FLUID LEVEL” in chapter 3.
5. Check:
• clutch lever operation
Soft or spongy feeling ® Bleed the
clutch system.
Refer to “BLEEDING THE HYDRAULIC
CLUTCH SYSTEM” in chapter 3.
aa
HYDRAULIC CLUTCH

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

7 - 57
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

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.
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

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