suspension YAMAHA YZF-R7 1999 Owners Manual

CHASSIS SPECIFICATIONSSPEC
2 - 13
Front suspension
Suspension type Telescopic fork ----
Front fork type Coil spring/oil damper ----
Front fork travel 120 mm (4.72 in) ----
Spring
Free length 240 mm (9.45 in) ----
Spacer length 127 mm (5.00 in) ----
Installed length 226 mm (8.90 in) ----
Spring rate (K1) 9.3 N/mm (0.95 kgf/mm, 53.2 lb/in)
Spring stroke (K1) 0 ~ 120 mm (0 ~ 4.72 in) ----
Optional spring available No ----
Fork oil
Recommended oil Suspension oil “01” or equivalent ----
Quantity (each front fork leg) 460 cm
3 (16.2 Imp oz, 15.6 US oz) ----
Level (from the top of the outer
tube, with the outer tube fully
down, and without the fork
spring)170 mm (6.69 in) ----
Damper adjusting rod locknut dis-
tance31 mm (1.22 in) ----
Spring preload adjusting positions
Minimum 0 [0 mm ( 0 in)] ----
Standard 14 [14 mm (0.55 in)] ----
Maximum 18-1/2 [18.5 mm (0.73 in)] ----
Rebound damping adjusting posi-
tions
Minimum* 17 ----
Standard* 6 ----
Maximum* 1 ----
Compression damping adjusting
positions
Minimum* 20 ----
Standard* 6 ----
Maximum* 1 ----
* from the fully turned-in positionItem Standard Limit

CHASSIS SPECIFICATIONSSPEC
2 - 14
Steering
Steering bearing type Angular ball bearings ----
Rear suspension
Suspension type Swingarm (link suspension) ----
Rear shock absorber assembly
typeCoil spring/gas-oil damper ----
Rear shock absorber assembly
travel63 mm (2.48 in) ----
Spring
Free length 160 mm (6.30 in) ----
Installed length 146 mm (5.75 in) ----
Spring rate (K1) 95 N/mm (9.69 kgf/mm, 543 lb/in) ----
Spring stroke (K1) 0 ~ 63 mm (0 ~ 2.48 in) ----
Optional spring available No ----
Standard spring preload gas/air
pressure 1,200 kPa (12 kgf/cm
2, 171 psi) ----
Spring preload adjusting positions
Minimum 0 [11 mm (0.43 in)] ----
Standard 6 [14 mm (0.55 in)] ----
Maximum 20 [21 mm (0.84 in)] ----
Rebound damping adjusting posi-
tions
Minimum* 50 ----
Standard* 10 ----
Maximum* 0 ----
Compression damping adjusting
positions
Minimum* 25 ----
Standard* 10 ----
Maximum* 0 ----
* from the fully turned-in position
Swingarm
Free play (at the end of the swing-
arm)
Radial ---- 1 mm
(0.04 in)
Axial ---- 1 mm
(0.04 in)
Drive chain
Model (manufacturer) 50ZVM (DAIDO) ----
Link quantity 118 ----
Drive chain slack 40 ~ 50 mm (1.57 ~ 1.97 in) ----
Maximum ten-link section 150.1 mm (5.91 in) ----Item Standard Limit

3 - 2
CHK
ADJ

PERIODIC MAINTENANCE AND LUBRICATION
INTERVALS
*
Since these items require special tools, data and technical skills, they should be serviced by a
Yamaha dealer.
NOTE:

• The air filter element needs more frequent service if you are riding in unusually wet or
dusty areas.
• Hydraulic brake system
– Replace the brake fluid or clutch fluid after disassembling the master cylinder, caliper cyl-
inder or release cylinder.
– Check the brake fluid or clutch fluid level and add fluid as required.
– Replace the master cylinder, caliper cylinder and release cylinder oil seals every two
years.
– Replace the brake hoses and clutch hose every four years, or if cracked or damaged.
15
*
Chassis fasteners
• Make sure that all nuts, bolts and screws are properly
tightened.
• Tighten if necessary.
ÖÖ
16 Sidestand
• Check operation.
• Lubricate and repair if necessary.
ÖÖ
17
*
Sidestand switch
• Check operation.
• Replace if necessary.
ÖÖÖ
18
*
Front fork
• Check operation and for oil leakage.
• Correct accordingly.
ÖÖ
19
*
Rear shock
absorber assembly
• Check operation and shock absorber for oil leakage.
• Replace shock absorber assembly if necessary.
ÖÖ
20
*
Rear suspension
relay arm and con-
necting arm pivot-
ing points
• Check operation.
• Lubricate with lithium soap base grease every 24,000
km or 24 months (whichever comes first).
ÖÖ
21
*
Electronic fuel
injection system
• Check engine idling speed, synchronization and
starter operation.
• Adjust if necessary.
ÖÖÖ
22 Engine oil
• Check oil level and vehicle for oil leakage.
• Correct if necessary.
• Change. (Warm engine before draining.)
ÖÖÖ
23Engine oil filter
cartridge
• Replace.
ÖÖ
24
*
Cooling system
• Check coolant level and vehicle for coolant leakage.
• Correct if necessary.
• Change coolant every 24,000 km 24 months (which-
ever comes first).
ÖÖ
No. ITEM CHECKS AND MAINTENANCE JOBSINITIAL
1,000 km EVERY
6,000 km or
6 months
(whichever
comes first)12,000 km or
12 months
(whichever
comes first)
3

3 - 47
CHK
ADJ
ADJUSTING THE FRONT FORK LEGS
EB304153
ADJUSTING THE FRONT FORK LEGS
The following procedure applies to both of
the front fork legs.
WARNINGWARNING
• Always adjust both front fork legs
evenly. Uneven adjustment can result
in poor handling and loss of stability.
• Securely support the motorcycle so
that there is no danger of it falling
over.
Spring preload
ACHTUNG:CAUTION:
• Grooves are provided to indicate the
adjustment position.
• Never go beyond the maximum or
minimum adjustment positions.
1. Adjust:
• spring preload
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 adjusting bolt 1 in direction
a or b.
NOTE:
With each turn of the adjusting bolt, the
installed length of the fork spring is
changed by 1 mm.
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 a
(turns in)Spring preload is
increased (suspension is
harder).
Direction b
(turns out)Spring preload is
decreased (suspension is
softer).
Adjusting positions
Minimum: 0 turns in direction*
Standard: 14 turns in direction*
Maximum: 18-1/2 turns in direction*
* after fully turning the adjusting
bolt in direction b
1
1

a a
b b

3 - 48
CHK
ADJ
ADJUSTING THE FRONT FORK LEGS
Rebound damping
ACHTUNG:CAUTION:
Never go beyond the maximum or mini-
mum adjustment positions.
1. Adjust:
• rebound damping
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 adjusting screw 1 in direc-
tion a or b.
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
Compression damping
ACHTUNG:CAUTION:
Never go beyond the maximum or mini-
mum adjustment positions.
1. Adjust:
• compression damping
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 adjusting screw 1 in direc-
tion a or b.
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 aRebound damping is
increased (suspension is
harder).
Direction bRebound damping is
decreased (suspension is
softer).
Adjusting positions
Minimum: 17 clicks out*
Standard: 6 clicks out*
Maximum: 1 clicks out*
* from the fully turned-in position
Direction aCompression damping is
increased (suspension is
harder).
Direction bCompression damping is
decreased (suspension is
softer).
Adjusting positions
Minimum: 20 clicks out*
Standard: 6 clicks out*
Maximum: 1 clicks out*
* from the fully turned-in position
a ab b 1

1

a a
b b
1
1

3 - 49
CHK
ADJ
EB304162
ADJUSTING THE REAR SHOCK
ABSORBER ASSEMBLY
WARNINGWARNING
Securely support the motorcycle so that
there is no danger of it falling over.
Spring preload
ACHTUNG:CAUTION:
Never go beyond the maximum or mini-
mum adjustment positions.
1. Adjust:
• spring preload
NOTE:
Adjust the spring preload with the spe-
cial wrench and extension bar included
in the owner’s tool kit.
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 adjusting knob 1 in direc-
tion a or b.
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 a
(turns in)Spring preload is
increased (suspension is
harder).
Direction b
(turns out)Spring preload is
decreased (suspension is
softer).
Adjusting positions
Minimum: 0 turns in*
Standard: 6 turns in *
Maximum: 20 turns in *
* from the fully turned-out position
1
1
a a
b b
ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY

3 - 50
CHK
ADJ
ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY
Rebound damping
ACHTUNG:CAUTION:
Never go beyond the maximum or mini-
mum adjustment positions.
1. Adjust:
• rebound damping
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 adjusting screw 1 in direc-
tion a or b.
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
Compression damping
ACHTUNG:CAUTION:
Never go beyond the maximum or mini-
mum adjustment positions.
1. Adjust:
• compression damping
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 adjusting screw 1 in direc-
tion a or b.
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 aRebound damping is
increased (suspension is
harder).
Direction bRebound damping is
decreased (suspension is
softer).
Adjusting positions
Minimum: 50 clicks out*
Standard: 10 clicks out*
Maximum: 0 clicks out*
* from the fully turned-in position
Direction aCompression damping is
increased (suspension is
harder).
Direction bCompression damping is
decreased (suspension is
softer).
Adjusting positions
Minimum: 25 clicks out*
Standard: 10 clicks out*
Maximum: 0 clicks out*
* from the fully turned-in position
1
1

a a
b b
a
a
b b1

1

3 - 51
CHK
ADJ
CHECKING THE TIRES
EB304170
CHECKING THE TIRES
The following procedure applies to both of
the tires.
1. Measure:
• tire pressure
Out of specification ® Regulate.
WARNINGWARNING
• The tire pressure should only be
checked and regulated when the tire
temperature equals the ambient air
temperature.
• The tire pressure and the suspension
must be adjusted according to the
total weight (including cargo, rider,
passenger and accessories) and the
anticipated riding speed.
• Operation of an overloaded motorcy-
cle could cause tire damage, an acci-
dent or an injury.
NEVER OVERLOAD THE MOTORCYCLE.
* total of cargo, rider and accessories
WARNINGWARNING
It is dangerous to ride with a worn-out
tire. When the tire tread reaches the
wear limit, replace the tire immediately.Basic weight
(with oil
and a full
fuel tank)207 kg (456 lb)
Maximum
load*317 kg (699 lb)
Cold tire
pressureFront Rear
Up to 90 kg
(198 lb)
load*250 kPa
(2.5 kgf/cm
2,
36 psi)250 kPa
(2.5 kgf/cm2,
36 psi)
90 kg (198 lb)
~ maximum
load*250 kPa
(2.5 kgf/cm
2,
36 psi)290 kPa
(2.9 kgf/cm2,
41 psi)
High-speed
riding250 kPa
(2.5 kgf/cm
2,
36 psi)250 kPa
(2.5 kgf/cm2,
36 psi)

3 - 54
CHK
ADJ
EB304200
CHECKING AND LUBRICATING THE
CABLES
The following procedure applies to all of
the cable sheaths and cables.
WARNINGWARNING
Damaged cable sheaths may cause the
cable to corrode and interfere with its
movement. Replace damaged cable
sheaths and cables as soon as possible.
1. Check:
• cable sheath
Damage ® Replace.
2. Check:
• cable operation
Rough movement ® Lubricate.
NOTE:
Hold the cable end upright and pour a
few drops of lubricant into the cable
sheath or use a suitable lubing device.
EB304210
LUBRICATING THE LEVERS AND PEDALS
Lubricate the pivoting point and metal-to-
metal moving parts of the levers and ped-
als.
EB304220
LUBRICATING THE SIDESTAND
Lubricate the pivoting point and metal-to-
metal moving parts of the sidestand.
EB304240
LUBRICATING THE REAR SUSPENSION
Lubricate the pivoting point and metal-to-
metal moving parts of the rear suspension.
Recommended lubricant
Engine oil or a suitable cable
lubricant
Recommended lubricant
Lithium soap base grease
Recommended lubricant
Lithium soap base grease
Recommended lubricant
Molybdenum disulfide grease
CHECKING AND LUBRICATING THE CABLES/
LUBRICATING THE LEVERS AND PEDALS/LUBRICATING THE
SIDESTAND/LUBRICATING THE REAR SUSPENSION