1999 YAMAHA YZF-R7 Owners Manual

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 - 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 - 34
CHAS

FRONT AND REAR BRAKES
Order Job/Part Q’ty Remarks
13 Brake hose 2
14 Brake master cylinder holder 1
15 Brake master cylinder 1
16 Front brake switch 1
For installation, reverse the removal
procedure.

7 - 35
CHAS

FRONT AND REAR BRAKES
EB702201
Order Job/Part Q’ty Remarks
Disassembling the front brake mas-
ter cylinder
Remove the parts in the order listed.
1
Dust boot 1
2
Circlip 1
3
Brake master cylinder kit 1
4
Brake master cylinder 1
For assembly, reverse the disassembly
procedure.

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 - 37
CHAS

FRONT AND REAR BRAKES
EB702203
Order Job/Part Q’ty Remarks
Disassembling the rear brake mas-
ter cylinder
Remove the parts in the order listed.
1
Brake master cylinder kit 1
2
Brake master cylinder 1
For assembly, reverse the disassembly
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