1999 YAMAHA YZF-R7 brakes

7 - 25
CHAS
EB702305
Order Job/Part Q’ty Remarks
Disassembling the rear brake caliperRemove the parts in the order listed.
1Brake pad clip 4
2Brake pad pin 2
3Brake pad spring 1
4Brake pad 2
5Brake caliper piston 2
6Brake caliper piston seal 4
7Bleed screw 2
For assembly, reverse the disassembly
procedure.
FRONT AND REAR BRAKES

7 - 26
CHAS
EB702317
DISASSEMBLING THE FRONT BRAKE
CALIPERS
The following procedure applies to both of
the brake calipers.
NOTE:
Before disassembling either brake cali-
per, drain the brake fluid from the entire
brake system.
1. Remove:
• union bolt 1
• copper washers 2
• brake hose
NOTE:
Put the end of the brake hose into a con-
tainer and pump out the brake fluid
carefully.
2. Remove:
• brake caliper pistons 1
• brake caliper piston seals 2
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. Secure the right side brake caliper
pistons with a piece of wood a.
b. Blow compressed air into the brake
hose joint opening b to force out the
left side pistons from the brake cali-
per.
WARNINGWARNING
• Never try to pry out the brake caliper
pistons.
• Do not loosen the bolts 3.
c. Remove the brake caliper piston
seals.
d. Repeat the previous steps to force out
the right side pistons from the brake
caliper.
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
FRONT AND REAR BRAKES

7 - 27
CHAS
EB702322
DISASSEMBLING THE REAR BRAKE
CALIPER
NOTE:
Before disassembling the brake caliper,
drain the brake fluid from the entire
brake system.
1. Remove:
• union bolt 1
• copper washers 2
• brake hose
NOTE:
Put the end of the brake hose into a con-
tainer and pump out the brake fluid
carefully.
2. Remove:
• brake caliper pistons 1
• brake caliper piston seals 2
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. Secure the right side brake caliper
piston with a piece of wood a.
b. Blow compressed air into the brake
hose joint opening b to force out the
left side piston from the brake caliper.
WARNINGWARNING
• Never try to pry out the brake caliper
pistons.
• Do not loosen the bolt 3.
c. Remove the brake caliper piston
seals.
d. Repeat the previous steps to force out
the right side piston from the brake
caliper.
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
FRONT AND REAR BRAKES

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