warning YAMAHA YZF-R7 1999 Service Manual

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 - 55
ENGOIL PAN AND OIL PUMP
2. Check:
• oil pump operation
Refer to “CHECKING THE OIL PUMP”.
EB411710
INSTALLING THE OIL PUMP
1. Install:
• oil pump 1
NOTE:
Install the oil/water pump assembly
drive chain onto the oil/water pump
assembly driven sprocket.
T R..12 Nm (1.2 m · kg, 8.7 ft · lb)
EB411720
INSTALLING THE OIL STRAINER
1. Install:
• oil strainer 1
NOTE:
The arrow a on the oil strainer housing
must point towards the front of the
engine.
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)
EB411730
INSTALLING THE OIL PAN
1. Install:
• dowel pins
• oil pan gasket
• oil pan 1
• oil level switch 2
• engine oil drain bolt 3
WARNINGWARNING
Always use new copper washers.
NOTE:
• Tighten the oil pan bolts in stages and
in a crisscross pattern.
• Lubricate the oil level switch O-ring
with lithium soap base grease.
New
T R..10 Nm (1.0 m · kg, 7.2 ft · lb)
T R..43 Nm (4.3 m · kg, 31 ft · lb)

4 - 73
ENGCONNECTING RODS AND PISTONS
9. Tighten:
• connecting rod nuts
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
• Tighten the connecting rod nuts in the
following way.
NOTE:
• How much the connecting rod nut is
tightened depends on how much the
connecting rod bolt stretches.
• Use a general micrometer 1 to mea-
sure the connecting rod bolts.
a. Before tightening the connecting rod
nut, measure the length of the con-
necting rod bolt with an accuracy of
three decimal places.
b. First tighten the connecting rod nut to
20 Nm (2.0 m • kg, 14 ft • lb), then up
to 40 Nm (4.0 m • kg, 29 ft • lb).
c. Measure the length of the connecting
rod bolt after tightening the connect-
ing rod nut and then calculate how
much the bolt has stretched.
d. Further tighten the connecting rod
nut until the connecting rod bolt has
stretched by between 0.170 and
0.175 mm.
ACHTUNG:CAUTION:
If the connecting rod nut cannot eventu-
ally be tightened to about 50 Nm (5.0 m
• kg, 36 ft • lb), too much MOLYKOTE
®‚
“G-n” paste may have been applied.
Loosen the connecting rod nut and
check the loosening torque. If the loos-
ening torque is less than 40 Nm (4.0 m •
kg, 29 ft • lb), too much MOLYKOTE
®‚
“G-n” paste was applied. In that case,
replace the connecting rod bolt with a
new one and apply a thin uniform layer
of MOLYKOTE
®‚ “G-n” paste to the
threads of the connecting rod bolt, the
contact area between the connecting
rod and the connecting rod bolt, and the
seat of the connnecting rod nut. Then,
tighten the connecting rod nut as
explained above.
WARNINGWARNING
Always replace the connecting rod bolt
with a new one if loosening the con-
necting rod nut after it was tightened.
Never use a connecting rod bolt more
than once.
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0.17 0
1

4 - 85
ENGTRANSMISSION
EB413100
REMOVING THE TRANSMISSION
1. Remove:
• main axle assembly 1
(with the Torx
Ò wrench T30)
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. Insert two bolts 2 of the proper size,
as shown in the illustration, into the
main axle assembly bearing housing.
b. Tighten the bolts until they contact
the crankcase surface.
c. Continue tightening the bolts until the
main axle assembly comes free from
the upper crankcase.
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EB413400
CHECKING THE SHIFT FORKS
The following procedure applies to all of
the shift forks.
1. Check:
• shift fork cam follower 1
• shift fork pawl 2
Bends/damage/scoring/wear ®
Replace the shift fork.
2. Check:
• shift fork guide bar
Roll the shift fork guide bar on a flat
surface.
Bends ® Replace.
WARNINGWARNING
Do not attempt to straighten a bent
shift fork guide bar.

7 - 3
CHAS

FRONT WHEEL AND BRAKE DISCS
EB700102
REMOVING THE FRONT WHEEL
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. Remove:
• left brake caliper
• right brake caliper
NOTE:

Do not squeeze the brake lever when
removing the brake calipers.
3. Elevate:
• front wheel
NOTE:

Place the motorcycle on a suitable stand
so that the front wheel is elevated.
EB700400
CHECKING THE FRONT WHEEL
1. Check:
• wheel axle
Roll the wheel axle on a flat surface.
Bends
®
Replace.
WARNINGWARNING

Do not attempt to straighten a bent
wheel axle.
2. Check:
• tire
• front wheel
Damage/wear
®
Replace.
Refer to “CHECKING THE TIRES” and
“CHECKING THE WHEELS” in chapter 3.

7 - 7
CHASFRONT WHEEL AND BRAKE DISCS
4. Install:
• brake calipers
WARNINGWARNING
Make sure that the brake hose is routed
properly.
T R..40 Nm (4.0 m · kg, 29 ft · lb)
EB700901
ADJUSTING THE FRONT WHEEL STATIC
BALANCE
NOTE:
• After replacing the tire, wheel or both,
the front wheel static balance should
be adjusted.
• Adjust the front wheel static balance
with the brake discs installed.
1. Remove:
• balancing weight(-s)
2. Find:
• front wheel’s heavy spot
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 front wheel on a suitable
balancing stand.
b. Spin the front wheel.
c. When the front wheel stops, put an
“X
1” mark at the bottom of the wheel.
d. Turn the front wheel 90˚ so that the
“X
1” mark is positioned as shown.
e. Release the front wheel.
f. When the front wheel stops, put an
“X
2” mark at the bottom of the wheel.
g. Repeat steps (a) through (d) several
times until all the marks come to rest
at the same spot.
h. The spot where all the marks come to
rest is the front wheel’s heavy spot
“X”.
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 - 12
CHAS
REAR WHEEL, BRAKE DISC, AND REAR WHEEL
SPROCKET
EB701100
REMOVING THE REAR WHEEL
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:
• brake caliper
NOTE:
Do not depress the brake pedal when
removing the brake caliper.
3. Remove:
• wheel axle nut
• washer
• wheel axle
• rear wheel
NOTE:
Push the rear wheel forward and
remove the drive chain from the rear
wheel sprocket.
EB701400
CHECKING THE REAR WHEEL
1. Check:
• wheel axle
• rear wheel
• wheel bearings
• oil seals
• brake disc
Refer to “FRONT WHEEL”.
2. Check:
• tire
• rear wheel
Damage/wear ® Replace.
Refer to “CHECKING THE TIRES” and
“CHECKING THE WHEELS” in chapter 3.

7 - 14
CHAS
REAR WHEEL, BRAKE DISC, AND REAR WHEEL
SPROCKET
EB701710
INSTALLING THE REAR WHEEL
1. Lubricate:
• wheel axle
• wheel bearings
• oil seal lips
Recommended lubricant
Lithium soap base grease
2. Adjust:
• drive chain slack a
Refer to “ADJUSTING THE DRIVE
CHAIN SLACK” in chapter 3.
Drive chain slack
40 ~ 50 mm (1.57 ~ 1.97 in)
3. Tighten:
• wheel axle
• wheel axle nut
• brake caliper bolts
WARNINGWARNING
Make sure that the brake hose is routed
properly.
EB701900
ADJUSTING THE REAR WHEEL STATIC
BALANCE
NOTE:
• After replacing the tire, wheel or both,
the rear wheel static balance should be
adjusted.
• Adjust the rear wheel static balance
with the brake disc and rear wheel
drive hub installed.
1. Adjust:
• rear wheel static balance
Refer to “FRONT WHEEL”.
T R..150 Nm (15.0 m · kg, 110 ft · lb)
T R..45 Nm (4.5 m · kg, 32 ft · lb)
T R..40 Nm (4.0 m · kg, 29 ft · lb)

7 - 26
CHAS
EB702317
DISASSEMBLING THE FRONT BRAKE
CALIPERS
The following procedure applies to both of
the brake calipers.
NOTE:
Before disassembling either brake cali-
per, drain the brake fluid from the entire
brake system.
1. Remove:
• union bolt 1
• copper washers 2
• brake hose
NOTE:
Put the end of the brake hose into a con-
tainer and pump out the brake fluid
carefully.
2. Remove:
• brake caliper pistons 1
• brake caliper piston seals 2
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. Secure the right side brake caliper
pistons with a piece of wood a.
b. Blow compressed air into the brake
hose joint opening b to force out the
left side pistons from the brake cali-
per.
WARNINGWARNING
• Never try to pry out the brake caliper
pistons.
• Do not loosen the bolts 3.
c. Remove the brake caliper piston
seals.
d. Repeat the previous steps to force out
the right side pistons from the brake
caliper.
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FRONT AND REAR BRAKES

7 - 27
CHAS
EB702322
DISASSEMBLING THE REAR BRAKE
CALIPER
NOTE:
Before disassembling the brake caliper,
drain the brake fluid from the entire
brake system.
1. Remove:
• union bolt 1
• copper washers 2
• brake hose
NOTE:
Put the end of the brake hose into a con-
tainer and pump out the brake fluid
carefully.
2. Remove:
• brake caliper pistons 1
• brake caliper piston seals 2
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. Secure the right side brake caliper
piston with a piece of wood a.
b. Blow compressed air into the brake
hose joint opening b to force out the
left side piston from the brake caliper.
WARNINGWARNING
• Never try to pry out the brake caliper
pistons.
• Do not loosen the bolt 3.
c. Remove the brake caliper piston
seals.
d. Repeat the previous steps to force out
the right side piston from the brake
caliper.
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
FRONT AND REAR BRAKES