Yamaha Yzf R1 2007 Manual

REAR BRAKE
4-39
3. Measure:
 Brake pad wear limit “a”
Out of specification → Replace the brake 
pads as a set.
4. Install:
 Brake pad shims
(onto the brake pads)
 Brake pads
 Brake pad spring
NOTE:
Always install new brake pads, brake pad 
shims, and a brake pad spring as a set.
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a. Connect a clear plastic hose “1” tightly to 
the bleed screw “2”. Put the other end of 
the hose into an open container.
b. Loosen the bleed screw and push the 
brake caliper pistons into the...

REAR BRAKE
4-40
EAS22590
REMOVING 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 “3”
 Brake caliper “4”
NOTE:
Put the end of the brake hose into a container 
and pump out the brake fluid carefully.
EAS22600
DISASSEMBLING THE REAR BRAKE CALI-
PER
1. Remove:
 Brake caliper piston “1”
 Brake caliper piston seals “2”
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a. Secure the brake...

REAR BRAKE
4-41
WARNING
EWA13610
Whenever a brake caliper is disassembled, 
replace the brake caliper piston seals.
2. Check:
 Brake caliper bracket “1”
Cracks/damage → Replace.
EAS22650
ASSEMBLING THE REAR BRAKE CALIPER
WARNING
EWA13620
 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 as they will cause the piston 
seals to swell and distort.
 Whenever a brake caliper is disassem-...

REAR BRAKE
4-42
 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.
5. Bleed:
 Brake system
Refer to BLEEDING THE HYDRAULIC 
BRAKE SYSTEM on page 3-25.
6. Check:
 Brake fluid level
Below the minimum level mark “a” → Add 
the recommended...

REAR BRAKE
4-43
4. Check:
 Brake hoses “1”
Cracks/damage/wear → Replace.
EAS22730
ASSEMBLING THE REAR BRAKE MASTER 
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 
EAS22740
INSTALLING THE REAR BRAKE MASTER 
CYLINDER
1. Install:
 Copper washers 
 Brake hoses
 Union bolt
WARNING
EWA13530
Proper brake hose routing is...

REAR BRAKE
4-44
 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.
3. Bleed:
 Brake system
Refer to BLEEDING THE HYDRAULIC 
BRAKE SYSTEM on page 3-25.
4. Check:
 Brake fluid level
Below the minimum level mark “a” → Add 
the recommended...

HANDLEBARS
4-45
EAS22850
HANDLEBARS
Removing the handlebars
Order Job/Parts to remove Q’ty Remarks
Front cowling Refer to GENERAL CHASSIS on page 4-1.
Side cowling Refer to GENERAL CHASSIS on page 4-1.
1 Grip end 2
2 Handlebar grip 1
3 Clutch switch connector 2 Disconnect.
4 Left handlebar switch 1
5Clutch cable 1
6 Clutch lever holder 1
7 Throttle cable housing 1
8 Throttle cable 2
9 Throttle grip 1
10 Front brake light switch lead connector 2 Disconnect.
11 Right handlebar switch 1
12 Clutch cable...

HANDLEBARS
4-46
18 Upper bracket bolt 2 Loosen.
19 Upper bracket pinch bolt 2 Loosen.
20 Steering stem nut 1 Loosen.
21 Upper bracket 1
22 Left handlebar  1
23 Right handlebar  1
For installation, reverse the removal proce-
dure.
Removing the handlebars
Order Job/Parts to remove Q’ty Remarks 

HANDLEBARS
4-47
EAS22870
REMOVING THE HANDLEBAR
1. Stand the vehicle on a level surface.
WARNING
EWA13120
Securely support the vehicle so that there 
is no danger of it falling over.
2. Remove:
 Handlebar grip “1”
NOTE:
Blow compressed air between the handlebar 
and the handlebar grip, and gradually push the 
grip off the handlebar.
3. Remove:
 Throttle cable housing “1”
 Throttle grip “2”
NOTE:
While removing the throttle cable housing, pull 
back the rubber cover “3”.
EAS22890
CHECKING THE...

HANDLEBARS
4-48
4. Install:
 Throttle grip
 Throttle cable housing “1”
 Throttle cables
NOTE:
Align the projection “a” on the throttle cable 
housing with the hole “b” in the right handlebar.
5. Install:
 Clutch lever holder “1”
NOTE:
Align the slit on the clutch lever holder with the 
punch mark “a” on the left handlebar.
6. Install:
 Left handlebar switch “1”
NOTE:
Align the projection “a” on the left handlebar 
switch with the hole “b” on the left handlebar.7. Install:
 Handlebar grip...