1999 YAMAHA YZF-R7 brake fluid

3 - 1
CHK
ADJ

INTRODUCTION/PERIODIC MAINTENANCE AND
LUBRICATION INTERVALS
EB300000
PERIODIC CHECKS AND ADJUSTMENTS
INTRODUCTION
This chapter includes all information necessary to perform recommended checks and adjust-
ments. If followed, these preventive maintenance procedures will ensure more reliable vehi-
cle operation, a longer service life and reduce the need for costly overhaul work. This
information applies to vehicles already in service as well as to new vehicles that are being
prepared for sale. All service technicians should be familiar with this entire chapter.
PERIODIC MAINTENANCE AND LUBRICATION INTERVALS
No. ITEM CHECKS AND MAINTENANCE JOBSINITIAL
1,000 km EVERY
6,000 km or
6 months
(whichever
comes first)12,000 km or
12 months
(whichever
comes first)
1
*
Fuel line
• Check fuel hoses for cracks or damage.
• Replace if necessary.
ÖÖ
2
*
Fuel filter
• Check condition.
• Replace if necessary.
Every 50,000 km
3 Spark plugs
• Check condition.
• Clean, regap or replace if necessary.
ÖÖÖ
4
*
Valves
• Check valve clearance.
• Adjust if necessary.
Every 42,000 km or 42 months (whichever
comes first)
5 Air filter element
• Clean or replace if necessary.
ÖÖ
6 Clutch
• Check operation and fluid leakage. (See NOTE on
page 3-2.)
• Correct if necessary.
ÖÖÖ
7
*
Front brake
• Check operation, fluid level and vehicle for fluid leak-
age. (See NOTE on page 3-2.)
• Correct accordingly.
• Replace brake pads if necessary.
ÖÖÖ
8
*
Rear brake
• Check operation, fluid level and vehicle for fluid leak-
age. (See NOTE on page 3-2.)
• Correct accordingly.
• Replace brake pads if necessary.
ÖÖÖ
9
*
Wheels
• Check balance, runout and for damage.
• Rebalance or replace if necessary.
ÖÖ
10
*
Tires
• Check tread depth and for damage.
• Replace if necessary.
• Check air pressure.
• Correct if necessary.
ÖÖ
11
*
Wheel bearings
• Check bearing for looseness or damage.
• Replace if necessary.
ÖÖ
12
*
Swingarm
• Check swingarm pivoting point for play.
• Correct if necessary.
• Lubricate with lithium soap base grease every 24,000
km or 24 months (whichever comes first).
ÖÖ
13 Drive chain
• Check chain slack.
• Adjust if necessary. Make sure that the rear wheel is
properly aligned.
• Clean and lubricate.
Every 1,000 km and after washing the
motorcycle or riding in rain.
14
*
Steering bearings
• Check bearing play and steering for roughness.
• Correct accordingly.
• Lubricate with lithium soap base grease every 24,000
km or 24 months (whichever comes first).
ÖÖ
3

3 - 2
CHK
ADJ

PERIODIC MAINTENANCE AND LUBRICATION
INTERVALS
*
Since these items require special tools, data and technical skills, they should be serviced by a
Yamaha dealer.
NOTE:

• The air filter element needs more frequent service if you are riding in unusually wet or
dusty areas.
• Hydraulic brake system
– Replace the brake fluid or clutch fluid after disassembling the master cylinder, caliper cyl-
inder or release cylinder.
– Check the brake fluid or clutch fluid level and add fluid as required.
– Replace the master cylinder, caliper cylinder and release cylinder oil seals every two
years.
– Replace the brake hoses and clutch hose every four years, or if cracked or damaged.
15
*
Chassis fasteners
• Make sure that all nuts, bolts and screws are properly
tightened.
• Tighten if necessary.
ÖÖ
16 Sidestand
• Check operation.
• Lubricate and repair if necessary.
ÖÖ
17
*
Sidestand switch
• Check operation.
• Replace if necessary.
ÖÖÖ
18
*
Front fork
• Check operation and for oil leakage.
• Correct accordingly.
ÖÖ
19
*
Rear shock
absorber assembly
• Check operation and shock absorber for oil leakage.
• Replace shock absorber assembly if necessary.
ÖÖ
20
*
Rear suspension
relay arm and con-
necting arm pivot-
ing points
• Check operation.
• Lubricate with lithium soap base grease every 24,000
km or 24 months (whichever comes first).
ÖÖ
21
*
Electronic fuel
injection system
• Check engine idling speed, synchronization and
starter operation.
• Adjust if necessary.
ÖÖÖ
22 Engine oil
• Check oil level and vehicle for oil leakage.
• Correct if necessary.
• Change. (Warm engine before draining.)
ÖÖÖ
23Engine oil filter
cartridge
• Replace.
ÖÖ
24
*
Cooling system
• Check coolant level and vehicle for coolant leakage.
• Correct if necessary.
• Change coolant every 24,000 km 24 months (which-
ever comes first).
ÖÖ
No. ITEM CHECKS AND MAINTENANCE JOBSINITIAL
1,000 km EVERY
6,000 km or
6 months
(whichever
comes first)12,000 km or
12 months
(whichever
comes first)
3

3 - 26
CHK
ADJCHANGING THE ENGINE OIL/
CHECKING THE CLUTCH FLUID LEVEL
15.Install:
• front cowling
• bottom cowling
Refer to “COWLINGS”.
EB303100
CHECKING THE CLUTCH FLUID LEVEL
1. Stand the motorcycle on a level surface.
NOTE:
• Place the motorcycle on a suitable
stand.
• Make sure that the motorcycle is
upright.
2. Check:
• clutch fluid level
Below the minimum level mark a ®
Add the recommended clutch fluid to
the proper level.
WARNINGWARNING
• Use only the designated clutch fluid.
Other fluids may cause the rubber
seals to deteriorate, causing leakage
and poor clutch performance.
• Refill with the same type of fluid. Mix-
ing fluids may result in a harmful
chemical reaction leading to poor
clutch performance.
• When refilling, be careful that water
does not enter the clutch fluid reser-
voir. Water will significantly lower the
boiling point of the fluid and could
cause vapor lock.
ACHTUNG:CAUTION:
Clutch fluid may damage painted sur-
faces and plastic parts. Always clean up
any split fluid immediately.
NOTE:
In order to ensure a correct reading of
the clutch fluid level, make sure that the
top of the clutch fluid reservoir is hori-
zontal.
Recommended clutch fluid
Brake fluid DOT 4aa

3 - 37
CHK
ADJADJUSTING THE REAR BRAKE/
CHECKING THE BRAKE FLUID LEVEL
ACHTUNG:CAUTION:
After adjusting the brake pedal position,
make sure that there is no brake drag.
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
3. Adjust:
• rear brake light switch
Refer to “ADJUSTING THE REAR
BRAKE LIGHT SWITCH”.
EB304020
CHECKING THE BRAKE FLUID LEVEL
1. Stand the motorcycle on a level surface.
NOTE:
• Place the motorcycle on a suitable
stand.
• Make sure that the motorcycle is
upright.
2. Check:
• brake fluid level
Below the minimum level mark a ®
Add the recommended brake fluid to
the proper level.
Front brake
õRear brake
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.
NOTE:
In order to ensure a correct reading of the
brake fluid level, make sure that the top of
the brake fluid reservoir is horizontal.
Recommended brake fluid
DOT 4

õ

3 - 39
CHK
ADJCHECKING THE BRAKE HOSES/
BLEEDING THE HYDRAULIC BRAKE SYSTEM
EB304062
CHECKING THE BRAKE HOSES
The following procedure applies to all of
the brake hoses and brake hose clamps.
1. Check:
• brake hose 1
Cracks/damage/wear ® Replace.
2. Check:
• brake hose clamp
Loose ® Tighten the clamp bolt.
3. Hold the motorcycle upright and apply
the brake several times.
4. Check:
• brake hose
Brake fluid leakage ® Replace the
damaged hose.
Refer to “FRONT AND REAR BRAKES”
in chapter 7.
EB304072
BLEEDING THE HYDRAULIC BRAKE
SYSTEM
WARNINGWARNING
Bleed the hydraulic brake system when-
ever:
• the brake system was disassembled,
• a brake hose was loosened, discon-
nected or replaced,
• the brake fluid level is very low,
• brake operation is faulty.
NOTE:
• Be careful not to spill any brake fluid or
allow the brake fluid reservoir to over-
flow.
• When bleeding the hydraulic brake
system, make sure that there is always
enough brake fluid before applying the
brake. Ignoring this precaution could
allow air to enter the hydraulic brake
system, considerably lengthening the
bleeding procedure.
• If bleeding is difficult, it may be neces-
sary to let the brake fluid settle for a
few hours. Repeat the bleeding proce-
dure when the tiny bubbles in the hose
have disappeared.

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CHK
ADJ
BLEEDING THE HYDRAULIC BRAKE SYSTEM
1. Bleed:
• hydraulic brake system
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. Fill the brake fluid reservoir to the
proper level with the recommended
brake fluid.
b. Install the brake fluid reservoir dia-
phragm.
c. Connect a clear plastic hose 1 tightly
to the bleed screw 2.
Front brake
õRear brake
d. Place the other end of the hose into a
container.
e. Slowly apply the brake several times.
f. Fully squeeze the brake lever or fully
depress the brake pedal and hold it in
position.
g. Loosen the bleed screw.
NOTE:
Loosening the bleed screw will release
the pressure and cause the brake lever
to contact the throttle grip or the brake
pedal to fully extend.
h. Tighten the bleed screw and then
release the brake lever or brake
pedal.
i. Repeat steps (e) to (h) until all of the
air bubbles have disappeared from
the brake fluid in the plastic hose.
j. Tighten the bleed screw to specifica-
tion.
k. Fill the brake fluid reservoir to the
proper level with the recommended
brake fluid.
Refer to “CHECKING THE BRAKE
FLUID LEVEL”.
WARNINGWARNING
After bleeding the hydraulic brake sys-
tem, check the brake operation.
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
T R..
Bleed screw
6 Nm (0.6 m • kg, 4.3 ft • lb)

õ

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CHK
ADJ
CHECKING AND ADJUSTING THE STEERING HEAD
3. Remove:
• bottom cowling
• front cowling
Refer to “COWLINGS”.
4. Remove:
• front brake fluid reservoir 1
• clutch fluid reservoir 2
2
2
1
1

5. Loosen:
• upper bracket pinch bolts 1
• handlebar pinch bolts 2
6. Remove:
• upper bracket bolts 3
• handlebars
(from the upper bracket)
1
1

3
3

2

2

7. Remove:
• steering stem nut 1
• washer 2
• upper bracket 3
2
2
1
1
3
3

8. Adjust:
• steering head
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. Remove the lock washer 1, the upper
ring nut 2, and the rubber washer 3.
b. Loosen the lower ring nut 4 and then
tighten it to specification with a ring
nut wrench 5.
NOTE:
Set the torque wrench at a right angle to
the steering nut wrench.
Steering nut wrench
90890-01403
T R..
Lower ring nut (initial tighten-
ing torque)
18 Nm (1.8 m • kg, 13 ft • lb)

7 - 17
CHASFRONT AND REAR BRAKES
EB702100
ACHTUNG:CAUTION:
Disc brake components rarely require
disassembly.
Therefore, always follow these preven-
tive measures:
• Never disassemble brake components
unless absolutely necessary.
• If any connection on the hydraulic
brake system is disconnected, the
entire brake system must be disas-
sembled, drained, cleaned, properly
filled, and bled after reassembly.
• Never use solvents on internal brake
components.
• Use only clean or new brake fluid for
cleaning brake components.
• Brake fluid may damage painted sur-
faces and plastic parts. Therefore,
always clean up any spilt brake fluid
immediately.
• Avoid brake fluid coming into contact
with the eyes as it can cause serious
injury.
First aid for brake fluid entering the
eyes:
• Flush with water for 15 minutes and
get immediate medical attention.
EB702112
REPLACING THE FRONT BRAKE PADS
The following procedure applies to both
brake calipers.
NOTE:
When replacing the brake pads, it is not
necessary to disconnect the brake hose
or disassemble the brake caliper.
1. Remove:
• brake hose holder 1
• brake caliper 2
1
1

2

2