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 brake caliper 
with your finger.c. Tighten the bleed screw.
d. Install a new brake pad shim “3” onto each 
new brake pad “4”.
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5. Install:
 Brake pad pin
Screw plug
 Brake caliper
6. 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.
7. Check:
 Brake pedal operation
Soft or spongy feeling → Bleed the brake 
system.
Refer to BLEEDING THE HYDRAULIC 
BRAKE SYSTEM on page 3-25.
Brake pad lining thickness
(inner)
6.0 mm (0.24 in)
Limit
1.0 mm (0.04 in)
Brake pad lining thickness
(outer)
6.0 mm (0.24 in)
Limit
1.0 mm (0.04 in)
Bleed screw
6 Nm (0.6 m·kg, 4.3 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) 
						

							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”
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Secure the brake caliper piston with a 
piece of wood “a”
b. Blow compressed air into the brake hose 
joint opening “b” to force out the piston from 
the brake caliper.
WARNING
EWA13550
 Cover the brake caliper piston with a rag. 
Be careful not to get injured when the pis-
ton is expelled from the brake caliper. Never try to pry out the brake caliper pis-
ton.
c. Remove the brake caliper piston seals.
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EAS22640
CHECKING THE REAR BRAKE CALIPER
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.
Recommended brake component
replacement 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 
						

							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-
bled, replace the brake caliper piston 
seals.
EAS22670
INSTALLING THE REAR BRAKE CALIPER
1. Install:
 Brake caliper “1”
(temporarily)
 Copper washers 
 Brake hose “2”
 Union bolt “3”
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.
2. Remove:
 Brake caliper
3. Install:
 Brake pad shims
 Brake pads
 Brake pad spring
 Brake pad pin
Screw plug
 Brake caliper
4. 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.
Recommended fluid
DOT 4
Rear brake hose union bolt
30 Nm (3.0 m·kg, 22 ft·lb)
New
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)
Recommended fluid
DOT 4 
						

							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 brake fluid to the proper 
level.
Refer to CHECKING THE BRAKE FLUID 
LEVEL on page 3-23.
7. Check:
 Brake pedal operation
Soft or spongy feeling → Bleed the brake 
system.
Refer to BLEEDING THE HYDRAULIC 
BRAKE SYSTEM on page 3-25.
EAS22700
REMOVING THE REAR BRAKE MASTER 
CYLINDER
1. Remove:
 Union bolt “1”
 Copper washers “2”
 Brake hose “3”
NOTE:
To collect any remaining brake fluid, place a 
container under the master cylinder and the 
end of the brake hose.
2. Remove:
 Brake master cylinder
EAS22720
CHECKING THE REAR 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”
Cracks/damage → Replace. 
						

							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 essential to 
insure safe vehicle operation. Refer to 
CABLE ROUTING on page 2-39.
CAUTION:
ECA14160
When installing the brake hose onto the 
brake master cylinder, make sure the brake 
pipe touches the projection “a” as shown.
2. Fill:
 Brake fluid reservoir
(to the maximum level mark “b”)
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.
Recommended fluid
DOT 4
Rear brake hose union bolt
30 Nm (3.0 m·kg, 22 ft·lb)
New
New
Recommended fluid
DOT 4 
						

							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 brake fluid to the proper 
level.
Refer to CHECKING THE BRAKE FLUID 
LEVEL on page 3-23.
5. Adjust:
 Brake pedal position
Refer to ADJUSTING THE REAR DISC 
BRAKE on page 3-22.
6. Adjust:
 Rear brake light operation timing
Refer to ADJUSTING THE REAR BRAKE 
LIGHT SWITCH on page 3-24. 
						

							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 holder 1
13 Brake fluid reservoir tank 1
14 Brake master cylinder holder 1
15 Brake master cylinder 1
16 Steering damper 1
17 Handlebar pinch bolt 2 Loosen. 
						

							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
1. Check:
 Left handlebar “1”
 Right handlebar “2”
Bends/cracks/damage → Replace.
WARNING
EWA13690
Do not attempt to straighten a bent handle-
bar as this may dangerously weaken it.
EAS22900
INSTALLING THE HANDLEBARS
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. Install:
 Right handlebar switch “1”
NOTE:
Align the projection “a” on the right handlebar 
switch with the hole “b” on the right handlebar.
3. Install:
 Brake master cylinder holder “1”
CAUTION:
ECA14260
 Install the brake master cylinder holder 
with the “UP” mark facing up.
 First, tighten the upper bolt, and then the 
lower bolt.
NOTE:
 Align the mating surfaces of the brake master 
cylinder holder with the punch mark “a” on 
the right handlebar.
 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.
Front brake master cylinder 
holder bolt
13 Nm (1.3 m·kg, 9.4 ft·lb) 
						

							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
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a. Apply a thin coat of rubber adhesive onto 
the end of the left handlebar.
b. Slide the handlebar grip over the end of the 
left handlebar.
c. Wipe off any excess rubber adhesive with a 
clean rag.
WARNING
EWA13700
Do not touch the handlebar grip until the 
rubber adhesive has fully dried.
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8. Adjust:
 Clutch cable free play
Refer to ADJUSTING THE CLUTCH 
CABLE FREE PLAY on page 3-14.
9. Adjust:
 Throttle cable free play
Refer to ADJUSTING THE THROTTLE 
CABLE FREE PLAY on page 3-8.
EAS4C81004
CHECKING THE STEERING DAMPER
1. Check:
 Steering damper body
Damage/oil leaks → Replace.
(It replace with the assembly.)
 Steering damper rod
Bends/scratch → Replace.
(It replace with the assembly.)
 Bearing
Damage/pitting → Replace.
(It replace with the assembly.)
Clutch lever free play
10.0–15.0 mm (0.39–0.59 in)
Throttle cable free play
3.0–5.0 mm (0.12–0.20 in)