Static error analysis plays a significant role on design，manufacturing and assembly of 7-DOF exoskeleton upper limb rehabilitation robot. The result of static error analysis usually affects the choice of measurement and optimization. The end movement of 7-DOF exoskeleton upper limb rehabilitation robot was investigated. The expression of terminal position and orientation error was obtained by theoretical calculation， and control variate method was applied to investigate the influences of length error and angle error. The terminal position and orientation error curve was drawn by MATLAB. The comparison analysis shows that angle error has more enormous impact than that of length error on terminal position and orientation accuracy. The angle accuracy should be pledged as high as possible for reducing processing cost and lessening risk of secondary injury.