Yamaha 2007 R6 Service

FRONT BRAKE
4-18
Removing the front brake master cylinder
Order Job/Parts to remove Q’ty Remarks
Brake fluidDrain.
Refer to “BLEEDING THE HYDRAULIC 
BRAKE SYSTEM” on page 3-24.
1 Brake fluid reservoir cap holder 1
2 Brake fluid reservoir cap 1
3 Brake fluid reservoir diaphragm holder 1
4 Brake fluid reservoir diaphragm 1
5 Brake fluid reservoir 1
6 Brake fluid reservoir hose 1
7Brake lever 1
8 Front brake light switch connector 2 Disconnect.
9 Front brake light switch 1
10 Front brake hose union bolt 1...

FRONT BRAKE
4-19
Disassembling the front brake master cylinder
Order Job/Parts to remove Q’ty Remarks
1 Brake master cylinder kit 1
2 Bleed screw 1
3 Brake master cylinder body 1
For assembly, reverse the disassembly pro-
cedure.
LS
1
32
1
T R..6 Nm (0.6 m  
kg, 4.3 ft  Ib)
New
New 

FRONT BRAKE
4-20
Removing the front brake calipers
Order Job/Parts to remove Q’ty Remarks
The following procedure applies to both of 
the front brake calipers.
Brake fluidDrain.
Refer to “BLEEDING THE HYDRAULIC 
BRAKE SYSTEM” on page 3-24.
1 Reflector assembly 1
2 Brake hose holder 1
3 Front brake hose union bolt 1
4 Copper washer 2
5 Front brake hose 1
6 Front brake caliper 1
For installation, reverse the removal proce-
dure. 

FRONT BRAKE
4-21
Disassembling the front brake calipers
Order Job/Parts to remove Q’ty Remarks
The following procedure applies to both of 
the front brake calipers.
1 Brake pad clip 2
2 Brake pad pin 1
3 Brake pad spring 1
4 Front brake pad 2
5 Brake caliper piston 4
6 Brake caliper piston seal 8
7 Bleed screw 1
For assembly, reverse the disassembly pro-
cedure. 

FRONT BRAKE
4-22
EAS22220
INTRODUCTION
WARNING
EWA14100
Disc brake components rarely require disas-
sembly. Therefore, always follow these pre-
ventive measures:
Never disassemble brake components un-
less 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 reas-
sembly.
Never use solvents on internal brake com-
ponents.
Use only clean or new brake fluid for clean-
ing...

FRONT BRAKE
4-23
d. Measure the brake disc deflection.
e. If out of specification, repeat the adjustment 
steps until the brake disc deflection is within 
specification.
f. If the brake disc deflection cannot be brought 
within specification, replace the brake disc.
         
6. Install:
Front wheel
Refer to “FRONT WHEEL” on page 4-4.
EAS22270
REPLACING THE FRONT BRAKE PADS
The following procedure applies to both brake 
calipers.
NOTE:
When replacing the brake pads, it is...

FRONT BRAKE
4-24
Refer to “CHECKING THE BRAKE FLUID 
LEVEL” on page 3-22.
5. Check:
Brake lever operation
Soft or spongy feeling → Bleed the brake sys-
tem.
Refer to “BLEEDING THE HYDRAULIC 
BRAKE SYSTEM” on page 3-24.
EAS22300
REMOVING THE FRONT BRAKE CALIPERS
The following procedure applies to both of the 
brake calipers.
NOTE:
Before removing the brake caliper, drain the 
brake fluid from the entire brake system.
1. Remove:
Front brake hose union bolt “1”
Copper washers “2”
Front brake hose “3”...

FRONT BRAKE
4-25
Brake caliper cylinders “2”
Scratches/wear → Replace the brake caliper 
assembly.
Brake caliper body “3”
Cracks/damage → Replace the brake caliper 
assembly.
Brake fluid delivery passages
(brake caliper body)
Obstruction → Blow out with compressed air.
WARNING
EWA13600
Whenever a brake caliper is disassembled, 
replace the piston seals.
EAS22410
ASSEMBLING THE FRONT BRAKE 
CALIPERS
WARNING
EWA13620
Before installation, all internal brake com-
ponents should be cleaned and lubricated...

FRONT BRAKE
4-26
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 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...

FRONT BRAKE
4-27
EAS22540
INSTALLING THE FRONT BRAKE MASTER 
CYLINDER
1. Install:
Front brake master cylinder “1”
Front brake master cylinder holder “2”
NOTE:
Install the brake master cylinder holder with the 
“UP” mark “a” facing up.
Align the mating surfaces of the brake master 
cylinder holder with the punch mark “b” on the 
handlebar.
First, tighten the upper bolt, then the lower bolt.
2. Install:
Front brake hose “1”
Copper washers “2” 
Front brake hose union bolt “3”
WARNING
EWA13530
Proper...