1999 YAMAHA YZF-R7 Owners Manual

7 - 39
CHAS

FRONT AND REAR BRAKES
2. Check:
• brake master cylinder kit
Damage/scratches/wear
®
Replace.

Front
õRear

õ
3. Check:
• brake fluid reservoir 1
Cracks/damage ® Replace.
• brake fluid reservoir diaphragm 2
Cracks/damage ® Replace.
4. Check:
• brake hoses
Cracks/damage/wear ® Replace.
EB702283
ASSEMBLING AND INSTALLING THE
FRONT BRAKE MASTER CYLINDER
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.
Recommended brake fluid
DOT 4

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 - 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 - 43
CHASHYDRAULIC CLUTCH
.EAS00305
HYDRAULIC CLUTCH
Order Job/Part Q’ty Remarks
Removing the clutch master cylin-
derRemove the parts in the order listed.
Clutch fluid Drain.
1 Clutch fluid reservoir cap 1
2 Clutch fluid reservoir diaphragm holder 1
3 Clutch fluid reservoir diaphragm 1
4 Clutch fluid reservoir 1
5 Clutch fluid reservoir hose 1
6 Dust seat 1
7 Circlip 1
8 Hose joint 1
9 Clutch lever 1
10 Clutch switch coupler 1
11 Union bolt 1

7 - 44
CHASHYDRAULIC CLUTCH
Order Job/Part Q’ty Remarks
12 Copper washer 2
13 Clutch hose 1
14 Clutch master cylinder holder 1
15 Clutch master cylinder 1
16 Clutch switch 1
For installation, reverse the removal
procedure.

7 - 45
CHASHYDRAULIC CLUTCH
Order Job/Part Q’ty Remarks
Disassembling the clutch master
cylinderRemove the parts in the order listed.
1Push rod 1
2Clutch master cylinder kit 1
3Clutch master cylinder 1
For assembly, reverse the disassembly
procedure.

7 - 46
CHAS
EAS00307
ACHTUNG:CAUTION:
Clutch components rarely require disas-
sembly.
Therefore, always follow these preven-
tive measures:
• Never disassemble clutch components
unless absolutely necessary.
• If any connection on the hydraulic
clutch system is disconnected, the
entire clutch system must be disas-
sembled, drained, cleaned, properly
filled, and bled after reassembly.
• Never use solvents on internal clutch
components.
• Use only clean or new clutch fluid for
cleaning clutch components.
• Clutch fluid may damage painted sur-
faces and plastic parts. Therefore,
always clean up any split fluid imme-
diately.
• Avoid clutch fluid coming into contact
with the eyes as it can cause serious
injury.
First aid for clutch fluid entering the
eyes:
Flush with water for 15 minutes and get
immediate medical attention.
EAS00308
CHECKING THE CLUTCH MASTER
CYLINDER
1. Check:
• clutch master cylinder
Damage/scratches/wear ® Replace the
clutch master cylinder.
• clutch fluid delivery passage
(clutch master cylinder body)
Obstruction ® Blow out with com-
pressed air.
2. Check:
• clutch master cylinder kit
Damage/scratches/wear ® Replace.
HYDRAULIC CLUTCH