1999 YAMAHA YZF-R7 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

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