1999 YAMAHA YZF-R7 brake

3 - 7
CHK
ADJ

Order Job/Part Q’ty Remarks
Removing the rear cowling
Remove the parts in the order listed.
1 Rear fender 1
2 Rear fender panel 1
3 Tail/brake light connector 2 Disconnect.
4 Rear turn signal connector 4 Disconnect.
5 Rear cowling 1
For installation, reverse the removal
procedure.
COWLINGS

3 - 26
CHK
ADJCHANGING THE ENGINE OIL/
CHECKING THE CLUTCH FLUID LEVEL
15.Install:
• front cowling
• bottom cowling
Refer to “COWLINGS”.
EB303100
CHECKING THE CLUTCH FLUID LEVEL
1. Stand the motorcycle on a level surface.
NOTE:
• Place the motorcycle on a suitable
stand.
• Make sure that the motorcycle is
upright.
2. Check:
• clutch fluid level
Below the minimum level mark a ®
Add the recommended clutch fluid to
the proper level.
WARNINGWARNING
• Use only the designated clutch fluid.
Other fluids may cause the rubber
seals to deteriorate, causing leakage
and poor clutch performance.
• Refill with the same type of fluid. Mix-
ing fluids may result in a harmful
chemical reaction leading to poor
clutch performance.
• When refilling, be careful that water
does not enter the clutch fluid reser-
voir. Water will significantly lower the
boiling point of the fluid and could
cause vapor lock.
ACHTUNG:CAUTION:
Clutch fluid may damage painted sur-
faces and plastic parts. Always clean up
any split fluid immediately.
NOTE:
In order to ensure a correct reading of
the clutch fluid level, make sure that the
top of the clutch fluid reservoir is hori-
zontal.
Recommended clutch fluid
Brake fluid DOT 4aa

3 - 36
CHK
ADJ
ADJUSTING THE REAR BRAKE
EB304001
CHASSIS
EB304010
ADJUSTING THE REAR BRAKE
1. Measure:
• brake pedal position
(distance a from the top of the brake
pedal to the bottom of the rider foot-
rest bracket)
Out of specification ® Adjust.
Brake pedal position (from the
top of the brake pedal to the
center of the rider footrest
bracket bolt)
31 ~ 36 mm (1.22 ~ 1.42 in)
a a
2. Adjust:
• brake pedal position
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. Loosen the locknut 1.
b. Turn the adjusting bolt 2 in direction
a or b until the specified brake pedal
position is obtained.
WARNINGWARNING
After adjusting the brake pedal position,
check that the end of the adjusting bolt
c is visible through the hole d.
c. Tighten the locknut 1 to specifica-
tion.
WARNINGWARNING
A soft or spongy feeling in the brake
pedal can indicate the presence of air in
the brake system. Before the vehicle is
operated, the air must be removed by
bleeding the brake system. Air in the
brake system will considerably reduce
braking performance and could result in
loss of control and possibly an accident.
Therefore, check and, if necessary,
bleed the brake system.Direction aBrake pedal is raised.
Direction bBrake pedal is lowered.
T R..
Locknut
16 Nm (1.6 m • kg, 11 ft • lb)

3 - 37
CHK
ADJADJUSTING THE REAR BRAKE/
CHECKING THE BRAKE FLUID LEVEL
ACHTUNG:CAUTION:
After adjusting the brake pedal position,
make sure that there is no brake drag.
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
3. Adjust:
• rear brake light switch
Refer to “ADJUSTING THE REAR
BRAKE LIGHT SWITCH”.
EB304020
CHECKING THE BRAKE FLUID LEVEL
1. Stand the motorcycle on a level surface.
NOTE:
• Place the motorcycle on a suitable
stand.
• Make sure that the motorcycle is
upright.
2. Check:
• brake fluid level
Below the minimum level mark a ®
Add the recommended brake fluid to
the proper level.
Front brake
õRear brake
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.
NOTE:
In order to ensure a correct reading of the
brake fluid level, make sure that the top of
the brake fluid reservoir is horizontal.
Recommended brake fluid
DOT 4

õ

3 - 38
CHK
ADJCHECKING THE BRAKE PADS/
ADJUSTING THE REAR BRAKE LIGHT SWITCH
EB304032
CHECKING THE BRAKE PADS
The following procedure applies to all of
the brake pads.
1. Operate the brake.
2. Check:
• front brake pad
• rear brake pad
Brake pad wear limit a
Wear limit reached ® Replace the
brake pads as a set.
Refer to “FRONT AND REAR BRAKES”
in chapter 7.
Front brake
õRear brake
Brake pad wear limit
0.5 mm (0.02 in)

õ
EB304050
ADJUSTING THE REAR BRAKE LIGHT
SWITCH
NOTE:
• The rear brake light switch is operated
by movement of the brake pedal.
• The rear brake light switch is properly
adjusted when the brake light comes
on just before the braking effect starts.
1. Check:
• rear brake light operation timing
Incorrect ® Adjust.
2. Adjust:
• rear brake light operation timing
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. Hold the main body 1 of the rear
brake light switch so that it does not
rotate and turn the adjusting nut 2 in
direction a or b until the rear brake
light comes on at the proper time.
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 aBrake light comes on
sooner.
Direction bBrake light comes on
later.

3 - 39
CHK
ADJCHECKING THE BRAKE HOSES/
BLEEDING THE HYDRAULIC BRAKE SYSTEM
EB304062
CHECKING THE BRAKE HOSES
The following procedure applies to all of
the brake hoses and brake hose clamps.
1. Check:
• brake hose 1
Cracks/damage/wear ® Replace.
2. Check:
• brake hose clamp
Loose ® Tighten the clamp bolt.
3. Hold the motorcycle upright and apply
the brake several times.
4. Check:
• brake hose
Brake fluid leakage ® Replace the
damaged hose.
Refer to “FRONT AND REAR BRAKES”
in chapter 7.
EB304072
BLEEDING THE HYDRAULIC BRAKE
SYSTEM
WARNINGWARNING
Bleed the hydraulic brake system when-
ever:
• the brake system was disassembled,
• a brake hose was loosened, discon-
nected or replaced,
• the brake fluid level is very low,
• brake operation is faulty.
NOTE:
• Be careful not to spill any brake fluid or
allow the brake fluid reservoir to over-
flow.
• When bleeding the hydraulic brake
system, make sure that there is always
enough brake fluid before applying the
brake. Ignoring this precaution could
allow air to enter the hydraulic brake
system, considerably lengthening the
bleeding procedure.
• If bleeding is difficult, it may be neces-
sary to let the brake fluid settle for a
few hours. Repeat the bleeding proce-
dure when the tiny bubbles in the hose
have disappeared.

3 - 40
CHK
ADJ
BLEEDING THE HYDRAULIC BRAKE SYSTEM
1. Bleed:
• hydraulic brake system
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. Fill the brake fluid reservoir to the
proper level with the recommended
brake fluid.
b. Install the brake fluid reservoir dia-
phragm.
c. Connect a clear plastic hose 1 tightly
to the bleed screw 2.
Front brake
õRear brake
d. Place the other end of the hose into a
container.
e. Slowly apply the brake several times.
f. Fully squeeze the brake lever or fully
depress the brake pedal and hold it in
position.
g. Loosen the bleed screw.
NOTE:
Loosening the bleed screw will release
the pressure and cause the brake lever
to contact the throttle grip or the brake
pedal to fully extend.
h. Tighten the bleed screw and then
release the brake lever or brake
pedal.
i. Repeat steps (e) to (h) until all of the
air bubbles have disappeared from
the brake fluid in the plastic hose.
j. Tighten the bleed screw to specifica-
tion.
k. Fill the brake fluid reservoir to the
proper level with the recommended
brake fluid.
Refer to “CHECKING THE BRAKE
FLUID LEVEL”.
WARNINGWARNING
After bleeding the hydraulic brake sys-
tem, check the brake operation.
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
T R..
Bleed screw
6 Nm (0.6 m • kg, 4.3 ft • lb)

õ

3 - 44
CHK
ADJ
CHECKING AND ADJUSTING THE STEERING HEAD
3. Remove:
• bottom cowling
• front cowling
Refer to “COWLINGS”.
4. Remove:
• front brake fluid reservoir 1
• clutch fluid reservoir 2
2
2
1
1

5. Loosen:
• upper bracket pinch bolts 1
• handlebar pinch bolts 2
6. Remove:
• upper bracket bolts 3
• handlebars
(from the upper bracket)
1
1

3
3

2

2

7. Remove:
• steering stem nut 1
• washer 2
• upper bracket 3
2
2
1
1
3
3

8. Adjust:
• steering head
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. Remove the lock washer 1, the upper
ring nut 2, and the rubber washer 3.
b. Loosen the lower ring nut 4 and then
tighten it to specification with a ring
nut wrench 5.
NOTE:
Set the torque wrench at a right angle to
the steering nut wrench.
Steering nut wrench
90890-01403
T R..
Lower ring nut (initial tighten-
ing torque)
18 Nm (1.8 m • kg, 13 ft • lb)