Yamaha Yzf R1 2007 Manual

							REAR WHEEL
4-19
WARNING
EWA13500
Make sure the brake hose is routed prop-
erly.
Rear wheel axle nut
150 Nm (15.0 m·kg, 108 ft·lb)
Rear brake caliper bolt (front 
side)
27 Nm (2.7 m·kg, 20 ft·lb)
Rear brake caliper bolt (rear 
side)
22 Nm (2.2 m·kg, 16 ft·lb) 
						

							FRONT BRAKE
4-20
EAS22210
FRONT BRAKE
Removing the front brake pads
Order Job/Parts to remove Q’ty Remarks
1 Brake hose holder 1
2 Front brake caliper 1
3 Brake pad clip 4
4 Brake pad pin 2
5 Brake pad spring 2
6 Brake pad 4
7 Bleed screw 1
For installation, reverse the removal proce-
dure. 
						

							FRONT BRAKE
4-21
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 3-25.
1 Stopper 1
2 Brake fluid reservoir cap 1
3 Brake fluid reservoir diaphragm holder 1
4 Brake fluid reservoir diaphragm 1
5 Brake fluid reservoir tank 1
6 Brake fluid reservoir hose 1
7Brake lever 1
8 Front brake light switch lead connector 1 Disconnect.
9 Union bolt 1
10 Copper washer 2
11 Brake hose 1
12 Brake master cylinder holder 1
13 Brake master cylinder 1
14 Front brake light switch 1
For installation, reverse the removal proce-
dure. 
						

							FRONT BRAKE
4-22
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. 
						

							FRONT BRAKE
4-23
Removing the front 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. 
						

							FRONT BRAKE
4-24
Disassembling the front brake calipers
Order Job/Parts to remove Q’ty Remarks
1 Brake pad clip 4
2 Brake pad pin 2
3 Brake pad spring 2
4 Brake pad 4
5 Brake caliper piston 6
6 Brake caliper piston seal 12
7 Bleed screw 1
For assembly, reverse the disassembly pro-
cedure. 
						

							FRONT BRAKE
4-25
EAS22220
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.
EAS22240
CHECKING THE FRONT BRAKE DISCS
The following procedure applies to both brake 
discs.
1. Remove:
 Front wheel
Refer to FRONT WHEEL on page 4-8.
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.
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a. Place the vehicle on a suitable stand so 
that the front wheel is elevated.
b. Before measuring the front brake disc 
deflection, turn the handlebar to the left or 
right to ensure that the front wheel is sta-
tionary.
c. Remove the brake caliper.
d. Hold the dial gauge at a right angle against 
the brake disc surface.
e. Measure the deflection 1.5 mm (0.06 in) 
below the edge of the brake disc.
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4. Measure:
 Brake disc thickness
Measure the brake disc thickness at a few 
different locations.
Out of specification → Replace.
5. Adjust:
 Brake disc deflection
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the brake disc.
b. Rotate the brake disc by one bolt hole.
c. Install the brake disc.
NOTE:
Tighten the brake disc bolts in stages and in a 
crisscross pattern.
Brake disc deflection limit
0.10 mm (0.0039 in)
Brake disc thickness limit
4.5 mm (0.18 in) 
						

							FRONT BRAKE
4-26
d. Measure the brake disc deflection.
e. If out of specification, repeat the adjust-
ment 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 4-8.
EAS22260
REPLACING THE FRONT 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:
 Brake hose holder “1”
 Brake caliper “2”
2. Remove:
 Brake pad clips “1”
 Brake pad pins “2”
 Brake pad springs “3”3. Remove:
 Brake pads “1”
4. Measure:
 Brake pad wear limit “a”
Out of specification → Replace the brake 
pads as a set.
5. Install:
 Brake pads
 Brake pad spring
Front brake disc bolt
18 Nm (1.8 m·kg, 13 ft·lb)
LOCTITE®
Brake pad lining thickness
(inner)
4.5 mm (0.18 in)
Limit
0.8 mm (0.03 in)
Brake pad lining thickness
(outer)
4.5 mm (0.18 in)
Limit
0.8 mm (0.03 in) 
						

							FRONT BRAKE
4-27
NOTE:
Always install new brake pads and a new 
brake pad spring as a set.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
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 brake caliper 
with your finger.
c. Tighten the bleed screw.
d. Install new brake pads and a new brake 
pad spring.
NOTE:
The arrow mark “a” on the brake pad springs 
must point in the direction of disc rotation.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
6. Install:
 Brake pad pins
 Brake pad clips
 Brake caliper
7. Check:
 Brake fluid levelBelow 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.
8. Check:
 Brake lever operation
Soft or spongy feeling → Bleed the brake 
system.
Refer to BLEEDING THE HYDRAULIC 
BRAKE SYSTEM on page 3-25.
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:
 Union bolt “1”
 Copper washers “2”
 Brake hose “3”
NOTE:
Put the end of the brake hose into a container 
and pump out the brake fluid carefully.
Bleed screw
6 Nm (0.6 m·kg, 4.3 ft·lb)
Front brake caliper bolt
35 Nm (3.5 m·kg, 25 ft·lb) 
						

							FRONT BRAKE
4-28
EAS22360
DISASSEMBLING THE FRONT BRAKE 
CALIPERS
The following procedure applies to both of the 
brake calipers.
1. Remove:
 Brake caliper pistons “1”
 Brake caliper piston seals “2”
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
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 caliper.
WARNING
EWA4C81005
 Never try to pry out the brake caliper pis-
tons.
 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.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS22390
CHECKING THE FRONT BRAKE CALIPERS
1. Check:
 Brake caliper pistons “1”
Rust/scratches/wear → Replace the brake 
caliper pistons.
 Brake caliper cylinders “2”
Scratches/wear → Replace the brake cali-
per assembly.
 Brake caliper body “3”
Cracks/damage → Replace the brake cali-
per 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 CALI-
PERS
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.
Recommended brake component replace-
ment schedule
Brake pads If necessary
Piston seals Every two years
Brake hoses Every four years
Brake fluidEvery two years and 
whenever the brake is 
disassembled