1999 YAMAHA YZF-R7 oil

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

7 - 51
CHAS
EAS00312
Order Job/Part Q’ty Remarks
Disassembling the clutch release
cylinderRemove the parts in the order listed.
1Dust seal 1
2Clutch release cylinder piston 1
3Spring 1
4Oil seal 1
5Bleed screw 1
For assembly, reverse the disassembly
procedure.
HYDRAULIC CLUTCH

7 - 52
CHAS
EAS00313
DISASSEMBLING THE CLUTCH RELEASE
CYLINDER
1. Remove:
• dust seal 1
• clutch release cylinder piston 2
• spring 3
• oil seal 4
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. Blow compressed air into the clutch
hose joint opening a to force out the
piston from the clutch release cylin-
der.
WARNINGWARNING
• Cover the clutch release cylinder with
a rag. Be careful not to get injured
when the piston is expelled from the
clutch release cylinder.
• Never try to pry out the clutch release
cylinder piston.
b. Remove the clutch release cylinder oil
seal.
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
EAS00314
CHECKING THE CLUTCH RELEASE
CYLINDER
1. Check:
• clutch release cylinder body 1
Cracks/damage ® Replace the clutch
release cylinder.
• clutch release cylinder 2
• clutch release cylinder piston 3
Rust/scratches/wear ® Replace the
clutch release cylinder and clutch
release cylinder piston as a set.
1
1

2
2

3
3

HYDRAULIC CLUTCH

7 - 53
CHAS
EAS00315
ASSEMBLING AND INSTALLING THE
CLUTCH RELEASE 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 as they will cause the oil
seal and dust seal to swell and distort.
• Whenever a clutch release cylinder is
disassembled, replace the oil seal and
dust seal.
Recommended clutch fluid
Brake fluid DOT 4
1. Check:
• copper washer 1
• clutch hose 2
• union bolt 3
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 release cylinder, make sure that
the pipe a touches the projection b.
2. Fill:
• clutch fluid reservoir
(with the specified amount of the rec-
ommended clutch fluid)
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.Recommended clutch fluid
Brake fluid DOT 4
2
2

3

3

a a
1
1

b b
New
T R..26 Nm (2.6 m · kg, 19 ft · lb)
HYDRAULIC CLUTCH

7 - 54
CHAS
• 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.
3. Bleed:
• clutch system
Refer to “BLEEDING THE HYDRAULIC
CLUTCH SYSTEM” in chapter 3.
4. 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.
5. 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 - 56
CHAS
EB703002
Order Job/Part Q’ty Remarks
Disassembling the front fork legsRemove the parts in the order listed.
The following procedure applies to
both of the front fork legs.
1 Cap bolt/O-ring 1/1
2 Straight key 1
3 Washer 1
4 Damper adjusting rod 1
5 Nut 1
6 Spring seat 1
7Spacer 1
8Fork spring 1
9 Outer tube 1
0Dust seal 1
A Oil seal clip 1
B Oil seal 1
CWasher 1
FRONT FORK

7 - 59
CHAS
• nut 2
• spring seat 3
• spacer
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. Press down on the spacer with the
fork spring compressor 4.
b. Install the rod holder 5 between the
nut 2 and the spring seat 3.
NOTE:
Use the side of the rod holder that is
marked “A”.
c. Loosen the nut.
d. Remove the cap bolt, straight key,
washer and damper adjusting rod.
e. Remove the rod holder and fork
spring compressor.
WARNINGWARNING
The fork spring is compressed.
f. Remove the nut, spring seat and
spacer.
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
Fork spring compressor
90890-01441
Rod holder
90890-01434
2. Drain:
• fork oil
NOTE:
Stroke the damper rod 1 several times
while draining the fork oil.
3. Remove:
• outer tube
(from inner tube)
4. Remove:
• dust seal
• oil seal clip 1
• oil seal
• washer
(with a flat-head screwdriver)
FRONT FORK