warning YAMAHA YZF-R7 1999 Workshop Manual

7 - 28
CHAS
EB702343
CHECKING THE FRONT AND REAR BRAKE
CALIPERS
1. Check:
• brake caliper pistons 1
Rust/scratches/wear ® Replace the
brake caliper.
• brake caliper cylinders 2
Scratches/wear ® Replace the brake
caliper.
• brake calipers
Cracks/damage ® Replace.
• brake fluid delivery passages
(brake caliper body)
Obstruction ® Blow out with com-
pressed air.
WARNINGWARNING
Whenever a brake caliper is disassem-
bled, replace the brake caliper piston
seals.
Front
õRear
Recommended brake component
replacement schedule
Brake pads If necessary
Piston seals Every two years
Brake hoses Every two years
Brake fluidEvery two years
and whenever the
brake is disassem-
bled

õ
2. Check:
• rear brake caliper bracket 1
Cracks/damage ® Replace.
1
1

FRONT AND REAR BRAKES

7 - 29
CHAS
EB702376
ASSEMBLING AND INSTALLING THE
FRONT BRAKE CALIPERS
The following procedure applies to both of
the brake calipers.
WARNINGWARNING
• Before installation, all internal brake
components should be cleaned and
lubricated with clean or new brake
fluid.
• Never use solvents on internal brake
components as they will cause the pis-
ton seals to swell and distort.
• Whenever a brake caliper is disassem-
bled, replace the brake caliper piston
seals.
Recommended brake fluid
DOT 4
1. Install:
• brake caliper 1
(temporarily)
• copper washers
• brake hose 2
• union bolt 3
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 caliper 1, make sure that the
brake pipe a touches the projection b
on the brake caliper.
2. Remove:
• brake caliper
New
T R..30 Nm (3.0 m · kg, 22 ft · lb)
3. Install:
• brake pads
• brake pad spring
• brake caliper
Refer to “REPLACING THE FRONT
BRAKE PADS”.
T R..40 Nm (4.0 m · kg, 29 ft · lb)
FRONT AND REAR BRAKES

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 - 31
CHAS

EB702378
ASSEMBLING AND INSTALLING THE REAR
BRAKE CALIPER
WARNINGWARNING

• Before installation, all internal brake
components should be cleaned and
lubricated with clean or new brake
fluid.
• Never use solvents on internal brake
components as they will cause the pis-
ton seals to swell and distort.
• Whenever a brake caliper is disassem-
bled, replace the brake caliper piston
seals.
Recommended brake fluid
DOT 4
1. Install:
• brake caliper
1
(temporarily)
• copper washers
• brake hose
2
• union bolt
3
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 caliper
1
, make sure that the
brake pipe
a
touches the projection
b
on the brake caliper.
2. Remove:
• brake caliper
3. Install:
• brake pads
• brake pad springs
• brake caliper
Refer to “REPLACING THE REAR
BRAKE PADS”.
New
T R..30 Nm (3.0 m · kg, 22 ft · lb)
T R..40 Nm (4.0 m · kg, 29 ft · lb)

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 - 39
CHAS

FRONT AND REAR BRAKES
2. Check:
• brake master cylinder kit
Damage/scratches/wear
®
Replace.

Front
õRear

õ
3. Check:
• brake fluid reservoir 1
Cracks/damage ® Replace.
• brake fluid reservoir diaphragm 2
Cracks/damage ® Replace.
4. Check:
• brake hoses
Cracks/damage/wear ® Replace.
EB702283
ASSEMBLING AND INSTALLING THE
FRONT BRAKE MASTER CYLINDER
WARNINGWARNING
• Before installation, all internal brake
components should be cleaned and
lubricated with clean or new brake
fluid.
• Never use solvents on internal brake
components.
Recommended brake fluid
DOT 4

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 - 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 - 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