1999 YAMAHA YZF-R7 Owners Manual

7 - 47
CHAS
3. Check:
• clutch fluid reservoir 1
Cracks/damage ® Replace.
• clutch fluid reservoir diaphragm 2
Cracks/damage ® Replace.
4. Check:
• clutch hose
Cracks/damage/wear ® Replace.
ASSEMBLING AND INSTALLING THE
CLUTCH MASTER 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.
Recommended clutch fluid
Brake fluid DOT 4
1. Install:
• clutch master cylinder 1
NOTE:
• Install the clutch master cylinder
holder with the “UP” mark facing up.
• Align the end of the clutch master cyl-
inder holder with the punch mark a in
the handlebar.
• First, tighten the upper bolt, then the
lower bolt.
UP UP
1
1

a a
HYDRAULIC CLUTCH

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 - 49
CHAS
4. Bleed:
• clutch system
Refer to “BLEEDING THE HYDRAULIC
CLUTCH SYSTEM” in chapter 3.
5. Check:
• clutch fluid level
Below the minimum level mark a ® Add
the recommended clutch fluid to the
proper level.
Refer to “CHECKING THE CLUTCH FLUID
LEVEL” in chapter 3.
6. Check:
• clutch lever operation
Soft or spongy feeling ® Bleed the
clutch system.
Refer to “BLEEDING THE HYDRAULIC
CLUTCH SYSTEM” in chapter 3.
aa
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 - 51
CHAS
EAS00312
Order Job/Part Q’ty Remarks
Disassembling the clutch release
cylinderRemove the parts in the order listed.
1Dust seal 1
2Clutch release cylinder piston 1
3Spring 1
4Oil seal 1
5Bleed screw 1
For assembly, reverse the disassembly
procedure.
HYDRAULIC CLUTCH

7 - 52
CHAS
EAS00313
DISASSEMBLING THE CLUTCH RELEASE
CYLINDER
1. Remove:
• dust seal 1
• clutch release cylinder piston 2
• spring 3
• oil seal 4
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. Blow compressed air into the clutch
hose joint opening a to force out the
piston from the clutch release cylin-
der.
WARNINGWARNING
• Cover the clutch release cylinder with
a rag. Be careful not to get injured
when the piston is expelled from the
clutch release cylinder.
• Never try to pry out the clutch release
cylinder piston.
b. Remove the clutch release cylinder oil
seal.
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
EAS00314
CHECKING THE CLUTCH RELEASE
CYLINDER
1. Check:
• clutch release cylinder body 1
Cracks/damage ® Replace the clutch
release cylinder.
• clutch release cylinder 2
• clutch release cylinder piston 3
Rust/scratches/wear ® Replace the
clutch release cylinder and clutch
release cylinder piston as a set.
1
1

2
2

3
3

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

7 - 54
CHAS
• 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.
3. Bleed:
• clutch system
Refer to “BLEEDING THE HYDRAULIC
CLUTCH SYSTEM” in chapter 3.
4. Check:
• clutch fluid level
Below the minimum level mark a ®
Add the recommended clutch fluid to
the proper level.
Refer to “CHECKING THE CLUTCH
FLUID LEVEL” in chapter 3.
5. Check:
• clutch lever operation
Soft or spongy feeling ® Bleed the
clutch system.
Refer to “BLEEDING THE HYDRAULIC
CLUTCH SYSTEM” in chapter 3.
aa
HYDRAULIC CLUTCH