YAMAHA YZF-R7 1999 Owners Manual

7 - 71
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.
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
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

7 - 72
CHAS
EB705001
STEERING HEAD
T R..13 Nm (1.3 m • kg, 9.4 ft • Ib)
T R..115 Nm (11.5 m • kg, 85 ft • Ib)
T R..18 Nm (1.8 kg •
m, 13 ft •
Ib)
9 Nm (0.9 kg
•
m, 6.5 ft •
Ib)
1st.
2nd.T R..19 Nm (1.9 m • kg, 13 ft • Ib)
LS1842
2 5
6
1 8
9
11
13
14
15
1810
3 16
14
17
12
7
20
LS
LS
19
Order Job/Part Q’ty Remarks
Removing the lower bracketRemove the parts in the order listed.
Front wheel Refer to “FRONT WHEEL AND BRAKE
DISCS”.
Front fork legs Refer to “FRONT FORK”.
1 Main switch coupler 2 Disconnect.
2 Upper bracket bolt 2
3 Left handlebar assembly 1
4 Right handlebar assembly 1
5 Steering stem nut 1
6 Upper bracket 1
7 Brake hose holder bolt 2
8 Lock washer 1
9 Upper ring nut 1
10 Rubber washer 1
STEERING HEAD

7 - 73
CHAS
T R..13 Nm (1.3 m • kg, 9.4 ft • Ib)
T R..115 Nm (11.5 m • kg, 85 ft • Ib)
T R..18 Nm (1.8 kg •
m, 13 ft •
Ib)
9 Nm (0.9 kg
•
m, 6.5 ft •
Ib)
1st.
2nd.T R..19 Nm (1.9 m • kg, 13 ft • Ib)
LS1842
2 5
6
1 8
9
11
13
14
15
1810
3 16
14
17
12
7
20
LS
LS
19
Order Job/Part Q’ty Remarks
11 Lower ring nut 1
12 Lower bracket 1
13 Bearing cover 1
14 Bearing inner race 2
15 Upper bearing 1
16 Lower bearing 1
17 Dust seal 1
18 Bearing outer race 2
19 Upper bearing housing 1
20 Lower bearing housing 1
For installation, reverse the removal
procedure.
STEERING HEAD

7 - 74
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

7 - 75
CHAS
EB705700
INSTALLING THE STEERING HEAD
1. Lubricate:
• upper bearing
• lower bearing
• bearing races
• O-ring
• dust seat lips
• bearing cover lips
• steering stem shreads
2. Install:
• lower ring nut 1
• rubber washer 2
• upper ring nut 3
• lock washer 4
Refer to “CHECKING AND ADJUSTING
THE STEERING HEAD” in chapter 3.
Recommended lubricant
Lithium soap base grease
3. Install:
• upper bracket
• steering stem nut
NOTE:
Temporarily tighten the steering stem
nut.
4. Install:
• front fork legs
Refer to “FRONT FORK”.
NOTE:
Temporarily tighten the upper and lower
bracket pinch bolts, and handlebar pinch
bolts.
5. Tighten:
• steering stem nut
• lower bracket pinch bolt
• upper bracket pinch bolt

• upper bracket bolt
• handlebar pinch bolt
T R..115 Nm (11.5 m · kg, 85 ft · lb)
T R..11 Nm (1.1 m · kg, 8.0 ft · lb)
T R..26 Nm (2.6 m · kg, 19 ft · lb)
T R..13 Nm (1.3 m · kg, 9.4 ft · lb)
T R..13 Nm (1.3 m · kg, 9.4 ft · lb)
STEERING HEAD

7 - 76
CHAS
EB706000
REAR SHOCK ABSORBER ASSEMBLY
Order Job/Part Q’ty Remarks
Removing the rear shock absorber
assemblyRemove the parts in the order listed.
1 Bolt 1
2 Self-locking nut/bolt 1/1
3 Self-locking nut/bolt 2/2
4 Self-locking nut/bolt 1/1
5 Rear shock absorber assembly 1
6 Self-locking nut/bolt 1/1
7 Connecting arm 2
8 Spacer/oil seal/bearing2/4/2
9 Sidestand 1
10 Self-locking nut/bolt/spacer1/1/1
11 Relay arm 1
12 Spacer/oil seal/bearing3/6/3
For installation, reverse the removal
procedure.
REAR SHOCK ABSORBER ASSEMBLY

7 - 77
CHAS
EB706101
HANDLING THE REAR SHOCK ABSORBER
AND GAS CYLINDER
WARNINGWARNING
This rear shock absorber and gas cylin-
der contain highly compressed nitro-
gen gas. Before handling the rear shock
absorber or gas cylinder, read and make
sure you understand the following
information. The manufacturer cannot
be held responsible for property dam-
age or personal injury that may result
from improper handling of the rear
shock absorber and gas cylinder.
• Do not tamper or attempt to open the
rear shock absorber or gas cylinder.
• Do not subject the rear shock absorber
or gas cylinder to an open flame or
any other source of high heat. High
heat can cause an explosion due to
excessive gas pressure.
• Do not deform or damage the rear
shock absorber or gas cylinder in any
way. If the rear shock absorber, gas
cylinder or both are damaged, damp-
ing performance will suffer.
EB706111
DISPOSING OF A REAR SHOCK ABSORBER
AND GAS CYLINDER
Gas pressure must be released before dis-
posing of a rear shock absorber and gas cyl-
inder. To release the gas pressure, press on
the gas valve needle with a suitable tool as
shown, until all of the gas is released (the
hissing has stopped).
WARNINGWARNING
Wear eye protection to prevent eye
damage from released gas or metal
chips.
REAR SHOCK ABSORBER ASSEMBLY

7 - 78
CHAS
EB706204
REMOVING THE REAR SHOCK ABSORBER
ASSEMBLY
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 rear wheel is elevated.
2. Remove:
• rear shock absorber assembly lower
bolt 1
• connecting arm-to-swingarm bolt 2
NOTE:
While removing the rear shock absorber
assembly lower bolt, hold the swingarm
so that it does not drop down.
2
2
2
2

1

1

3. Remove:
• rear shock absorber assembly upper
bolt 1
• rear shock absorber assembly
NOTE:
Raise the swingarm and then remove
the rear shock absorber assembly from
between the swingarm.
1
1

EB706401
CHECKING THE REAR SHOCK ABSORBER
ASSEMBLY AND GAS CYLINDER
1. Check:
• rear shock absorber rod
Bends/damage ® Replace the rear
shock absorber assembly.
• rear shock absorber
Gas leaks/oil leaks ® Replace the rear
shock absorber assembly.
• spring
Damage/wear ® Replace the rear
shock absorber assembly.
• gas cylinder
Damage/gas leaks ® Replace.
• bushings
Damage/wear ® Replace.
• dust seals
Damage/wear ® Replace.
• bolts
Bends/damage/wear ® Replace.
REAR SHOCK ABSORBER ASSEMBLY

7 - 79
CHAS
CHECKING THE RELAY ARM AND
CONNECTING ARM
1. Check:
• relay arm 1
• connecting arm 2
Damage/wear ® Replace.
• bearings
• oil seals
Damage/pitting ® Replace.
• spacers
Damage/scratches ® Replace.
1
1
2
2

2

2

EB706701
INSTALLING THE REAR SHOCK ABSORBER
ASSEMBLY
1. Lubricate:
• bearings
• oil seals
• spacers
2. Install:
• relay arm
• connecting arms
• rear shock absorber assembly
NOTE:
When installing the rear shock absorber
assembly, lift up the swingarm.
3. Tighten:
• relay arm-to-frame nut
• relay arm-to-connecting arm nut
• connecting arm-to-swingarm nut
• rear shock absorber assembly upper nut
• rear shock absorber assembly lower nut
Recommended lubricant
Molybdenum disulfide grease
T R..40 Nm (4.0 m · kg, 29 ft · lb)
T R..40 Nm (4.0 m · kg, 29 ft · lb)
T R..40 Nm (4.0 m · kg, 29 ft · lb)
T R..40 Nm (4.0 m · kg, 29 ft · lb)
T R..40 Nm (4.0 m · kg, 29 ft · lb)
REAR SHOCK ABSORBER ASSEMBLY

7 - 80
CHAS
EB707000
SWINGARM AND DRIVE CHAIN
Order Job/Part Q’ty Remarks
Removing the swingarm and drive
chainRemove the parts in the order listed.
Drive sprocket Refer to “ENGINE” in chapter 4.
Rear wheel Refer to “REAR WHEEL, BRAKE DISC,
AND REAR WHEEL SPROCKET”.
Rear shock absorber assembly Refer to “REAR SHOCK ABSORBER
ASSEMBLY”.
1 Spacer 1
2 Adjusting bolt/locknut 2/2
3 Left drive chain puller 1
4 Right drive chain puller 1
5 Drive chain guard 1 1
6 Drive chain guard 3 1
7 Brake hose holder 3
8 Pivot shaft nut/washer 1/1
9 Right pivot shaft boss 1
SWINGARM AND DRIVE CHAIN