YAMAHA YZF-R7 1999 Owners Manual

7 - 41
CHASFRONT AND REAR BRAKES
ACHTUNG:CAUTION:
Brake fluid may damage painted sur-
faces and plastic parts. Therefore,
always clean up any spilt brake fluid
immediately.
4. Bleed:
• brake system
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
5. 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.
6. Check:
• brake lever operation
Soft or spongy feeling ® Bleed the
brake system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
EB702290
ASSEMBLING THE REAR BRAKE MASTER
CYLINDER
1. Install:
• copper washers
• brake hoses
• union bolt
WARNINGWARNING
Proper brake hose routing is essential to
insure safe motorcycle operation. Refer
to “CABLE ROUTING”.
ACHTUNG:CAUTION:
When installing the brake hose onto the
brake master cylinder, make sure that
the brake pipe touches the projection a
as shown.
aa
New
T R..30 Nm (3.0 m · kg, 22 ft · lb)

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 - 43
CHASHYDRAULIC CLUTCH
.EAS00305
HYDRAULIC CLUTCH
Order Job/Part Q’ty Remarks
Removing the clutch master cylin-
derRemove the parts in the order listed.
Clutch fluid Drain.
1 Clutch fluid reservoir cap 1
2 Clutch fluid reservoir diaphragm holder 1
3 Clutch fluid reservoir diaphragm 1
4 Clutch fluid reservoir 1
5 Clutch fluid reservoir hose 1
6 Dust seat 1
7 Circlip 1
8 Hose joint 1
9 Clutch lever 1
10 Clutch switch coupler 1
11 Union bolt 1

7 - 44
CHASHYDRAULIC CLUTCH
Order Job/Part Q’ty Remarks
12 Copper washer 2
13 Clutch hose 1
14 Clutch master cylinder holder 1
15 Clutch master cylinder 1
16 Clutch switch 1
For installation, reverse the removal
procedure.

7 - 45
CHASHYDRAULIC CLUTCH
Order Job/Part Q’ty Remarks
Disassembling the clutch master
cylinderRemove the parts in the order listed.
1Push rod 1
2Clutch master cylinder kit 1
3Clutch master cylinder 1
For assembly, reverse the disassembly
procedure.

7 - 46
CHAS
EAS00307
ACHTUNG:CAUTION:
Clutch components rarely require disas-
sembly.
Therefore, always follow these preven-
tive measures:
• Never disassemble clutch components
unless absolutely necessary.
• If any connection on the hydraulic
clutch system is disconnected, the
entire clutch system must be disas-
sembled, drained, cleaned, properly
filled, and bled after reassembly.
• Never use solvents on internal clutch
components.
• Use only clean or new clutch fluid for
cleaning clutch components.
• Clutch fluid may damage painted sur-
faces and plastic parts. Therefore,
always clean up any split fluid imme-
diately.
• Avoid clutch fluid coming into contact
with the eyes as it can cause serious
injury.
First aid for clutch fluid entering the
eyes:
Flush with water for 15 minutes and get
immediate medical attention.
EAS00308
CHECKING THE CLUTCH MASTER
CYLINDER
1. Check:
• clutch master cylinder
Damage/scratches/wear ® Replace the
clutch master cylinder.
• clutch fluid delivery passage
(clutch master cylinder body)
Obstruction ® Blow out with com-
pressed air.
2. Check:
• clutch master cylinder kit
Damage/scratches/wear ® Replace.
HYDRAULIC CLUTCH

7 - 47
CHAS
3. Check:
• clutch fluid reservoir 1
Cracks/damage ® Replace.
• clutch fluid reservoir diaphragm 2
Cracks/damage ® Replace.
4. Check:
• clutch hose
Cracks/damage/wear ® Replace.
ASSEMBLING AND INSTALLING THE
CLUTCH MASTER 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.
Recommended clutch fluid
Brake fluid DOT 4
1. Install:
• clutch master cylinder 1
NOTE:
• Install the clutch master cylinder
holder with the “UP” mark facing up.
• Align the end of the clutch master cyl-
inder holder with the punch mark a in
the handlebar.
• First, tighten the upper bolt, then the
lower bolt.
UP UP
1
1

a a
HYDRAULIC CLUTCH

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

7 - 49
CHAS
4. Bleed:
• clutch system
Refer to “BLEEDING THE HYDRAULIC
CLUTCH SYSTEM” in chapter 3.
5. 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.
6. 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 - 50
CHAS
EAS00311
Order Job/Part Q’ty Remarks
Removing the clutch release cylin-
derRemove the parts in the order listed.
Bottom cowling Refer to “COWLINGS” in chapter 3.
Clutch fluid Drain.
1 Starter knob 1
2 Union bolt 1
3 Copper washer 2
4 Clutch hose 1
5 Clutch release cylinder assembly 1
6 Dowel pin 2
For installation, reverse the removal
procedure.
HYDRAULIC CLUTCH