1999 YAMAHA YZF-R7 washer fluid

7 - 33
CHAS

FRONT AND REAR BRAKES
EB702200
Order Job/Part Q’ty Remarks
Removing the front brake master
cylinder and brake fluid reservoir
Remove the parts in the order listed.
Brake fluid Drain.
1 Brake fluid reservoir cap stopper 1
2 Brake fluid reservoir cap 1
3 Brake fluid reservoir diaphragm
holder1
4 Brake fluid reservoir diaphragm 1
5 Brake fluid reservoir 1
6 Brake fluid reservoir hose 1
7 Circlip 1
8 Hose joint 1
9 Brake lever 1
10 Front brake switch connector 2 Disconnect.
11 Union bolt 1
12 Copper washer 3

7 - 36
CHAS

FRONT AND REAR BRAKES
EB702202
Order Job/Part Q’ty Remarks
Removing the rear brake master cyl-
inder and brake fluid reservoir
Remove the parts in the order listed.
Brake fluid Drain.
1 Brake fluid reservoir cap 1
2 Brake fluid reservoir diaphragm holder 1
3 Brake fluid reservoir diaphragm 1
4 Brake fluid reservoir 1
5 Plastic clamp 1
6 Plastic locking tie 1
7 Brake fluid reservoir hose 1
8 Hose joint 1
9 Oil seal 1
10 Union bolt 1
11 Copper washer 2
12 Brake hose 1
13 Brake master cylinder 1
For installation, reverse the removal
procedure.

7 - 38
CHAS

FRONT AND REAR BRAKES
EB702210
DISASSEMBLING THE FRONT BRAKE
MASTER CYLINDER
NOTE:

Before disassembling the front brake
master cylinder, drain the brake fluid
from the entire brake system.
1. Remove:
• union bolt
1
• copper washers
2
• brake hoses
3
NOTE:

To collect any remaining brake fluid,
place a container under the master cylin-
der and the end of the brake hose.
EB702220
DISASSEMBLING THE REAR BRAKE
MASTER CYLINDER
1. Remove:
• union bolt
1
• copper washers
2
• brake hose
3
NOTE:

To collect any remaining brake fluid,
place a container under the master cylin-
der and the end of the brake hose.
3
3

1

1

2
2


EB702243
CHECKING THE FRONT AND REAR BRAKE
MASTER CYLINDERS
The following procedure applies to both of
the brake master cylinders.
1. Check:
• brake master cylinder
Damage/scratches/wear
®
Replace.
• brake fluid delivery passages
(brake master cylinder body)
Obstruction
®
Blow out with com-
pressed air.

Front
õ
Rear

õ

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 - 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 - 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

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