lock YAMAHA YZF-R7 1999 Service Manual

ENG
4 - 83
TRANSMISSION
Order Job/Part Q’ty Remarks
Disassembling the drive axle assem-
blyRemove the parts in the order listed.
1 Washer 1
2 1st wheel gear 1
3 Spacer 1
4 5th wheel gear 1
5 Circlip 3
6 Washer 3
7 3rd wheel gear 1
8 Toothed spacer 2
9 Toothed lock washer 1
@ Toothed lock washer retainer 1

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)

7 - 9
CHAS
REAR WHEEL, BRAKE DISC, AND REAR WHEEL
SPROCKET
EB701000
REAR WHEEL, BRAKE DISC, AND REAR WHEEL SPROCKET
Order Job/Part Q’ty Remarks
Removing the rear wheelRemove the parts in the order listed.
1 Brake caliper 1
2 Locknut (left and right) 2 Loosen.
3 Adjusting bolt (left and right) 2 Loosen.
4 Wheel axle nut 2
5 Washer 1
6 Rear wheel axle 1
7 Rear wheel 1
8 Brake caliper bracket 1
For installation, reverse the removal
procedure.
NOTE:
Place the motorcycle on a suitable
stand so that the rear wheel is ele-
vated.

7 - 13
CHAS
REAR WHEEL, BRAKE DISC, AND REAR WHEEL
SPROCKET
3. Measure:
• radial wheel runout
• lateral wheel runout
Refer to “FRONT WHEEL”.
Over the specified limits ® Replace.
Max. radial wheel runout
1.0 mm (0.04 in)
Max. lateral wheel runout
0.5 mm (0.02 in)
EB701430
CHECKING THE REAR WHEEL DRIVE HUB
1. Check:
• rear wheel drive hub 1
Cracks/damage ® Replace.
• rear wheel drive hub dampers 2
Damage/wear ® Replace.
EB701440
CHECKING AND REPLACING THE REAR
WHEEL SPROCKET
1. Check:
• rear wheel sprocket
More than 1/4 tooth a wear ® Replace
the rear wheel sprocket.
Bent teeth ® Replace the rear wheel
sprocket.
b
Correct
1Drive chain roller
2Rear wheel sprocket
2. Replace:
• rear wheel sprocket
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 self-locking nuts and the
rear wheel sprocket.
b. Clean the rear wheel drive hub with a
clean cloth, especially the surfaces
that contact the sprocket.
c. Install the new rear wheel sprocket.
NOTE:
Tighten the self-locking nuts in stages
and in a crisscross pattern.
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..
Rear wheel sprocket self-lock-
ing nut
150 Nm (15.0 m • kg, 110 ft • lb)

7 - 30
CHAS
4. Fill:
• brake fluid reservoir
(with the specified amount of the rec-
ommended brake fluid)
WARNINGWARNING
• Use only the designated brake fluid.
Other brake fluids may cause the rub-
ber seals to deteriorate, causing leak-
age and poor brake performance.
• Refill with the same type of brake fluid
that is already in the system. Mixing
brake fluids may result in a harmful
chemical reaction, leading to poor
brake performance.
• When refilling, be careful that water
does not enter the brake fluid reser-
voir. Water will significantly lower the
boiling point of the brake fluid and
could cause vapor lock.
ACHTUNG:CAUTION:
Brake fluid may damage painted sur-
faces and plastic parts. Therefore,
always clean up any spilt brake fluid
immediately.
5. Bleed:
• brake system
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
Recommended brake fluid
DOT 4
6. Check:
• brake fluid level
Below the minimum level mark a ®
Add the recommended brake fluid to
the proper level.
Refer to “CHECKING THE BRAKE
FLUID LEVEL” in chapter 3.
7. Check:
• brake lever operation
Soft or spongy feeling ® Bleed the
brake system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
FRONT AND REAR BRAKES

7 - 32
CHAS

4. Fill:
• brake fluid reservoir
(with the specified amount of the rec-
ommended brake fluid)
WARNINGWARNING

• Use only the designated brake fluid.
Other brake fluids may cause the rub-
ber seals to deteriorate, causing leak-
age and poor brake performance.
• Refill with the same type of brake fluid
that is already in the system. Mixing
brake fluids may result in a harmful
chemical reaction, leading to poor
brake performance.
• When refilling, be careful that water
does not enter the brake fluid reser-
voir. Water will significantly lower the
boiling point of the brake fluid and
could cause vapor lock.
ACHTUNG:CAUTION:

Brake fluid may damage painted sur-
faces and plastic parts. Therefore,
always clean up any spilt brake fluid
immediately.
5. Bleed:
• brake system
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
Recommended brake fluid
DOT 4
6. Check:
• brake fluid level
Below the minimum level mark
a

®
Add the recommended brake fluid to
the proper level.
Refer to “CHECKING THE BRAKE
FLUID LEVEL” in chapter 3.
7. Check:
• brake pedal operation
Soft or spongy feeling
®
Bleed the
brake system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
FRONT AND REAR BRAKES

7 - 36
CHAS

FRONT AND REAR BRAKES
EB702202
Order Job/Part Q’ty Remarks
Removing the rear brake master cyl-
inder and brake fluid reservoir
Remove the parts in the order listed.
Brake fluid Drain.
1 Brake fluid reservoir cap 1
2 Brake fluid reservoir diaphragm holder 1
3 Brake fluid reservoir diaphragm 1
4 Brake fluid reservoir 1
5 Plastic clamp 1
6 Plastic locking tie 1
7 Brake fluid reservoir hose 1
8 Hose joint 1
9 Oil seal 1
10 Union bolt 1
11 Copper washer 2
12 Brake hose 1
13 Brake master cylinder 1
For installation, reverse the removal
procedure.

7 - 40
CHASFRONT AND REAR BRAKES
1. Install:
• brake master cylinder 1
NOTE:
• Install the brake master cylinder holder
with the “UP” mark facing up.
• Align the end of the brake master cyl-
inder holder with the punch mark a in
the right handlebar.
• First, tighten the upper bolt, then the
lower bolt.
1a
T R..13 Nm (1.3 m · kg, 9.4 ft · lb)
2. Install:
• copper washers
• brake hose
• union bolt
WARNINGWARNING
Proper brake hose routing is essential to
insure safe motorcycle operation. Refer
to “CABLE ROUTING”.
NOTE:
• While holding the brake hose, tighten
the union bolt as shown.
• Turn the handlebars to the left and to
the right to make sure that the brake
hose does not touch other parts (e.g.,
wire harness, cables, leads). Correct if
necessary.
New
T R..30 Nm (3.0 m · kg, 22 ft · lb)
3. Fill:
• brake fluid reservoir
(with the specified amount of the rec-
ommended brake fluid)
WARNINGWARNING
• Use only the designated brake fluid.
Other brake fluids may cause the rub-
ber seals to deteriorate, causing leak-
age and poor brake performance.
• Refill with the same type of brake fluid
that is already in the system. Mixing
brake fluids may result in a harmful
chemical reaction, leading to poor
brake performance.
• When refilling, be careful that water
does not enter the brake fluid reser-
voir. Water will significantly lower the
boiling point of the brake fluid and
could cause vapor lock.
Recommended brake fluid
DOT 4

7 - 42
CHASFRONT AND REAR BRAKES
2. Fill:
• brake fluid reservoir
WARNINGWARNING
• Use only the designated brake fluid.
Other brake fluids may cause the rub-
ber seals to deteriorate, causing leak-
age and poor brake performance.
• Refill with the same type of brake fluid
that is already in the system. Mixing
brake fluids may result in a harmful
chemical reaction, leading to poor
brake performance.
• When refilling, be careful that water
does not enter the reservoir. Water
will significantly lower the boiling
point of the brake fluid and could
cause vapor lock.
ACHTUNG:CAUTION:
Brake fluid may damage painted sur-
faces and plastic parts. Therefore,
always clean up any spilt brake fluid
immediately.
3. Bleed:
• brake system
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
Recommended brake fluid
DOT 4
4. Check:
• brake fluid level
Below the minimum level mark a ®
Add the recommended brake fluid to
the proper level.
Refer to “CHECKING THE BRAKE
FLUID LEVEL” in chapter 3.
5. Adjust:
• brake pedal position
Refer to “ADJUSTING THE REAR
BRAKE” in chapter 3.
6. Adjust:
• rear brake light operation timing
Refer to “ADJUSTING THE REAR
BRAKE LIGHT SWITCH” in chapter 3.

7 - 48
CHAS
2. Install:
• copper washers
• clutch hose 1
• union bolt 2
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 master cylinder, make sure
that the pipe a touches the projection
b.
2
2

a
a
1 1
b
b
New
T R..26 Nm (2.6 m · kg, 19 ft · lb)
3. Fill:
• clutch fluid reservoir
(with the specified amount of the rec-
ommended clutch fluid)
Recommended clutch fluid
Brake fluid DOT 4
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.
• 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.
HYDRAULIC CLUTCH