1999 YAMAHA YZF-R7 washer fluid

3 - 33
CHK
ADJ
CHANGING THE COOLANT
EB303240
CHANGING THE COOLANT
1. Remove:
• bottom cowling
• front cowling
Refer to “COWLINGS”.
2. Remove:
• coolant reservoir bolts 1
• coolant reservoir cap 2
NOTE:
When draining the coolant from the
coolant reservoir, be sure to tilt the res-
ervoir so that coolant cannot flow
through the coolant reservoir breather
hose 3.
3. Drain:
• coolant
(from the coolant reservoir)
4. Install:
• coolant reservoir bolts
2
2

1

1

5. Remove:
• radiator cap 1
WARNINGWARNING
A hot radiator is under pressure. There-
fore, do not remove the radiator cap
when the engine is hot. Scalding hot
fluid and steam may be blown out,
which could cause serious injury. When
the engine has cooled, open the radiator
cap as follows:
Place a thick rag or a towel over the
radiator cap and slowly turn the radia-
tor cap counterclockwise toward the
detent to allow any residual pressure to
escape. When the hissing sound has
stopped, turn the radiator cap counter-
clockwise while pressing down on it
and then remove it.
1
1

6. Remove:
• coolant drain bolt 1
(along with the copper washer)
7. Drain:
• coolant

3 - 44
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 - 22
CHAS
EB702301
Order Job/Part Q’ty Remarks
Removing the front brake calipersRemove the parts in the order listed.
The following procedure applies to
both of the front brake calipers.
Brake fluid Drain.
1 Union bolt 1
2 Copper washer 2
3 Brake hose 1
4 Brake caliper 1
For installation, reverse the removal
procedure.
FRONT AND REAR BRAKES

7 - 24
CHAS
EB702304
Order Job/Part Q’ty Remarks
Removing the rear brake caliperRemove the parts in the order listed.
Brake fluid Drain.
1 Union bolt 1
2 Copper washer 2
3 Brake hose 1
4 Brake caliper 1
For installation, reverse the removal
procedure.
FRONT AND REAR BRAKES

7 - 26
CHAS
EB702317
DISASSEMBLING THE FRONT BRAKE
CALIPERS
The following procedure applies to both of
the brake calipers.
NOTE:
Before disassembling either brake cali-
per, drain the brake fluid from the entire
brake system.
1. Remove:
• union bolt 1
• copper washers 2
• brake hose
NOTE:
Put the end of the brake hose into a con-
tainer and pump out the brake fluid
carefully.
2. Remove:
• brake caliper pistons 1
• brake caliper piston seals 2
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. Secure the right side brake caliper
pistons with a piece of wood a.
b. Blow compressed air into the brake
hose joint opening b to force out the
left side pistons from the brake cali-
per.
WARNINGWARNING
• Never try to pry out the brake caliper
pistons.
• Do not loosen the bolts 3.
c. Remove the brake caliper piston
seals.
d. Repeat the previous steps to force out
the right side pistons from the brake
caliper.
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
FRONT AND REAR BRAKES

7 - 27
CHAS
EB702322
DISASSEMBLING THE REAR BRAKE
CALIPER
NOTE:
Before disassembling the brake caliper,
drain the brake fluid from the entire
brake system.
1. Remove:
• union bolt 1
• copper washers 2
• brake hose
NOTE:
Put the end of the brake hose into a con-
tainer and pump out the brake fluid
carefully.
2. Remove:
• brake caliper pistons 1
• brake caliper piston seals 2
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. Secure the right side brake caliper
piston with a piece of wood a.
b. Blow compressed air into the brake
hose joint opening b to force out the
left side piston from the brake caliper.
WARNINGWARNING
• Never try to pry out the brake caliper
pistons.
• Do not loosen the bolt 3.
c. Remove the brake caliper piston
seals.
d. Repeat the previous steps to force out
the right side piston from the brake
caliper.
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
FRONT AND REAR BRAKES

7 - 29
CHAS
EB702376
ASSEMBLING AND INSTALLING THE
FRONT BRAKE CALIPERS
The following procedure applies to both of
the brake calipers.
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
New
T R..30 Nm (3.0 m · kg, 22 ft · lb)
3. Install:
• brake pads
• brake pad spring
• brake caliper
Refer to “REPLACING THE FRONT
BRAKE PADS”.
T R..40 Nm (4.0 m · kg, 29 ft · lb)
FRONT AND REAR BRAKES

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