Yamaha Yzf R1 2007 Manual

							FRONT BRAKE
4-29
 Whenever a brake caliper is disassem-
bled, replace the brake caliper piston 
seals.
EAS22450
INSTALLING THE FRONT BRAKE CALI-
PERS
The following procedure applies to both of the 
brake calipers.
1. Install:
 Brake pads
 Brake pad springs
 Brake pad pins
2. Install:
 Brake caliper “1”
 Copper washers 
 Brake hose “2”
 Union bolt “3”
 Brake hose holder
WARNING
EWA13530
Proper brake hose routing is essential to 
insure safe vehicle operation. Refer to 
CABLE ROUTING on page 2-39.
CAUTION:
ECA14170
When installing the brake hose onto the 
brake caliper “1”, make sure the brake pipe 
“a” touches the projection “b” on the brake 
caliper.3. Fill:
 Brake fluid reservoir
(with the specified amount of the recom-
mended brake fluid)
WARNING
EWA13090
 Use only the designated brake fluid. 
Other brake fluids may cause the rubber 
seals to deteriorate, causing leakage 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 perfor-
mance.
 When refilling, be careful that water does 
not enter the brake fluid reservoir. Water 
will significantly lower the boiling point of 
the brake fluid and could cause vapor 
lock.
CAUTION:
ECA13540
Brake fluid may damage painted surfaces 
and plastic parts. Therefore, always clean 
up any spilt brake fluid immediately.
4. Bleed:
 Brake system
Refer to BLEEDING THE HYDRAULIC 
BRAKE SYSTEM on page 3-25.
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 on page 3-23.
Recommended fluid
DOT 4
Front brake caliper bolt
35 Nm (3.5 m·kg, 25 ft·lb)
Front brake hose union bolt
30 Nm (3.0 m·kg, 22 ft·lb)
Front brake hose holder
6 Nm (0.6 m·kg, 4.3 ft·lb)
New
Recommended fluid
DOT 4 
						

							FRONT BRAKE
4-30
6. Check:
 Brake lever operation
Soft or spongy feeling → Bleed the brake 
system.
Refer to BLEEDING THE HYDRAULIC 
BRAKE SYSTEM on page 3-25.
EAS22490
REMOVING THE FRONT BRAKE MASTER 
CYLINDER
NOTE:
Before removing the front brake master cylin-
der, drain the brake fluid from the entire brake 
system.
1. Disconnect:
 Brake switch coupler “1”
(from the brake switch)
2. Remove:
 Union bolt “2”
 Copper washers “3”
 Brake hoses “4”
NOTE:
To collect any remaining brake fluid, place a 
container under the master cylinder and the 
end of the brake hose.
3. Remove:
 Brake master cylinder holder
 Brake master cylinder
EAS22510
CHECKING THE FRONT BRAKE MASTER 
CYLINDER
1. Check:
 Brake master cylinder
Damage/scratches/wear → Replace.
 Brake fluid delivery passages
(brake master cylinder body)
Obstruction → Blow out with compressed 
air.
2. Check:
 Brake master cylinder kit
Damage/scratches/wear → Replace.
3. Check:
 Brake fluid reservoir tank “1”
Cracks/damage → Replace.
 Brake fluid reservoir diaphragm “2”
Damage/wear → Replace.
4. Check:
 Brake hose “3”
Cracks/damage/wear → Replace. 
						

							FRONT BRAKE
4-31
EAS22520
ASSEMBLING THE FRONT BRAKE MAS-
TER CYLINDER
WARNING
EWA13520
 Before installation, all internal brake com-
ponents should be cleaned and lubricated 
with clean or new brake fluid.
 Never use solvents on internal brake 
components.
1. Instal:
 Brake master cylinder kit 
EAS22540
INSTALLING THE FRONT BRAKE MASTER 
CYLINDER
1. Install:
 Brake master cylinder “1”
 Brake master cylinder holder “2”
NOTE:
 Install the brake master cylinder holder with 
the “UP” mark “a” facing up.
 Align the end of the brake master cylinder 
holder with the punch mark “b” on the han-
dlebar.
 First, tighten the upper bolt, then the lower 
bolt.
 There should be 2–2.5 mm (0.08–0.10 in) of 
clearance between the right handlebar 
switch and the brake master cylinder holder.2. Install:
 Copper washers 
 Brake hose
 Union bolt
WARNING
EWA13530
Proper brake hose routing is essential to 
insure safe vehicle operation. Refer to 
CABLE ROUTING on page 2-39.
NOTE:
 While holding the brake hose, tighten the 
union bolt as shown.
 Turn the handlebar to the left and right to 
make sure the brake hose does not touch 
other parts (e.g., wire harness, cables, 
leads). Correct if necessary.
3. Fill:
 Brake fluid reservoir
(with the specified amount of the recom-
mended brake fluid)
Recommended fluid
DOT 4
Front brake master cylinder 
holder bolt
13 Nm (1.3 m·kg, 9.4 ft·lb)
New
Front brake hose union bolt
30 Nm (3.0 m·kg, 22 ft·lb)
a. 36°
b. 3 mm (0.12 in)
Recommended fluid
DOT 4
New 
						

							FRONT BRAKE
4-32
WARNING
EWA13090
 Use only the designated brake fluid. 
Other brake fluids may cause the rubber 
seals to deteriorate, causing leakage 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 perfor-
mance.
 When refilling, be careful that water does 
not enter the brake fluid reservoir. Water 
will significantly lower the boiling point of 
the brake fluid and could cause vapor 
lock.
CAUTION:
ECA13540
Brake fluid may damage painted surfaces 
and plastic parts. Therefore, always clean 
up any spilt brake fluid immediately.
4. Bleed:
 Brake system
Refer to BLEEDING THE HYDRAULIC 
BRAKE SYSTEM on page 3-25.
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 on page 3-23.
6. Check:
 Brake lever operation
Soft or spongy feeling → Bleed the brake 
system.
Refer to BLEEDING THE HYDRAULIC 
BRAKE SYSTEM on page 3-25. 
						

							REAR BRAKE
4-33
EAS22550
REAR BRAKE
Removing the rear brake pads
Order Job/Parts to remove Q’ty Remarks
1 Screw plug 1
2 Brake pad pin 1
3 Rear brake caliper 1
4 Brake pad shim 4
5 Brake pad 2
6 Bleed screw 1
7 Brake pad spring 1
For installation, reverse the removal proce-
dure. 
						

							REAR BRAKE
4-34
Removing the rear brake master cylinder
Order Job/Parts to remove Q’ty Remarks
Brake fluidDrain.
Refer to BLEEDING THE HYDRAULIC 
BRAKE SYSTEM on page 3-25.
1 Footrest plate 1
2 Brake fluid reservoir cap 1
3 Rear brake fluid reservoir diaphragm holder 1
4 Rear brake fluid reservoir diaphragm 1
5 Brake fluid reservoir tank 1
6 Brake fluid reservoir hose 1
7 Hose joint 1
8Bush 1
9 Union bolt 1
10 Copper washer 2
11 Brake hose 1
12 Brake master cylinder 1
For installation, reverse the removal proce-
dure. 
						

							REAR BRAKE
4-35
Disassembling the rear brake master cylinder
Order Job/Parts to remove Q’ty Remarks
1 Brake master cylinder kit 1
2 Hose joint 1
3Bush 1
4 Brake master cylinder body 1
For assembly, reverse the disassembly pro-
cedure. 
						

							REAR BRAKE
4-36
Removing the rear brake calipers
Order Job/Parts to remove Q’ty Remarks
Brake fluidDrain.
Refer to BLEEDING THE HYDRAULIC 
BRAKE SYSTEM on page 3-25.
1 Union bolt 1
2 Copper washer 2
3 Brake hose 1
4 Brake caliper 1
For installation, reverse the removal proce-
dure. 
						

							REAR BRAKE
4-37
Disassembling the rear brake calipers
Order Job/Parts to remove Q’ty Remarks
1 Screw plug 1
2 Brake pad pin 1
3 Brake pad 2
4 Brake pad shim 4
5 Brake pad spring 1
6 Brake caliper piston 1
7 Brake caliper piston seal 2
8 Bleed screw 1
For assembly, reverse the disassembly pro-
cedure. 
						

							REAR BRAKE
4-38
EAS22560
INTRODUCTION
WARNING
EWA14100
Disc brake components rarely require dis-
assembly. Therefore, always follow these 
preventive measures:
 Never disassemble brake components 
unless absolutely necessary.
 If any connection on the hydraulic brake 
system is disconnected, the entire brake 
system must be disassembled, 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 surfaces 
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.
EAS22570
CHECKING THE REAR BRAKE DISC
1. Remove:
 Rear wheel
Refer to REAR WHEEL on page 4-14.
2. Check:
Brake disc
Damage/galling → Replace.
3. Measure:
 Brake disc deflection
Out of specification → Correct the brake 
disc deflection or replace the brake disc.
Refer to CHECKING THE FRONT BRAKE 
DISCS on page 4-25.
4. Measure:
 Brake disc thickness
Measure the brake disc thickness at a few 
different locations.
Out of specification → Replace.
Refer to CHECKING THE FRONT BRAKE 
DISCS on page 4-25.5. Adjust:
 Brake disc deflection
Refer to CHECKING THE FRONT BRAKE 
DISCS on page 4-25.
6. Install:
 Rear wheel
Refer to REAR WHEEL on page 4-14.
EAS22580
REPLACING THE REAR BRAKE PADS
NOTE:
When replacing the brake pads, it is not neces-
sary to disconnect the brake hose or disas-
semble the brake caliper.
1. Remove :
 Screw plug “1”
 Brake pad pin “2”
 Brake caliper “3”
 Brake pad spring
2. Remove :
 Brake pads “1”
(along with the brake pad shims “2”)
Brake disc deflection limit
0.15 mm (0.0059 in)
Brake disc thickness limit
4.5 mm (0.18 in)
Rear brake disc bolt
30 Nm (3.0 m·kg, 22 ft·lb)
LOCTITE®