2004 YAMAHA YZF-R1S brakes

4-20
FRONT AND REAR BRAKESCHAS
NOTE:
NOTE: REPLACING THE REAR BRAKE PADS
When replacing the brake pads, it is not neces-
sary to disconnect the brake hose or disas-
semble the brake caliper.
1. Remove :

screw plug
1

brake pad pin 2

brake caliper 3

brake pad spring
2. Remove :

brake pads
1
(along with the brake pad shims 2)
3. Measure :

brake pad wear limit
a
Out of specification
Replace the brake
pads as a set.
Brake pad wear limit
1.0 mm (0.04 in)
4. Install :

brake pad shims
(onto the brake pads)

brake pads

brake pad spring
Always install new brake pads, brake pad
shims, and a brake pad spring as a set.
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4-21
FRONT AND REAR BRAKESCHAS
27 Nm (2.7 m
kg, 20 ft
lb)
22 Nm (2.2 m
kg, 16 ft
lb)
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.
Bleed screw
5 Nm (0.5 m
kg, 3.6 ft
lb)
d. Install a new brake pad shim
3 onto each
new brake pad
4.
5. Install:

rear brake caliper (front)
rear brake caliper (rear)

brake pad pin

screw plug
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” in chapter 3.
7. Check:

brake pedal operation
Soft or spongy feeling
Bleed the brake sys-
tem.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
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4-22
FRONT AND REAR BRAKESCHAS
Order Job / Part Q’ty Remarks
1
2
3
4
5
6
7
8
9Removing the front brake master
cylinder
Brake fluid
Stopper
Brake fluid reservoir cap
Brake fluid reservoir diaphragm holder
Brake fluid reservoir diaphragm
Brake fluid reservoir tank
Brake fluid reservoir hose
Brake lever
Front brake switch connector
Union bolt1
1
1
1
1
1
1
2
1Remove the parts in the order listed.
Drain.
Refer to “CHANGING THE BRAKE
FLUID” in chapter 3.
Disconnect.
3.8 Nm (0.38 m
kg, 2.7 ft
lb)
1.2 Nm (0.12 m
kg, 0.9 ft
lb)
13 Nm (1.3 m
kg, 9.4 ft
lb)
30 Nm (3.0 m
kg, 22 ft
lb)
EAS00584
FRONT BRAKE MASTER CYLINDER
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4-23
FRONT AND REAR BRAKESCHAS
Order Job / Part Q’ty Remarks
10
11
12
13
14Copper washer
Brake hose
Brake master cylinder bracket
Brake master cylinder
Front brake light switch2
1
1
1
1
For installation, reverse the removal
procedure.
3.8 Nm (0.38 m
kg, 2.7 ft
lb)
1.2 Nm (0.12 m
kg, 0.9 ft
lb)
13 Nm (1.3 m
kg, 9.4 ft
lb)
30 Nm (3.0 m
kg, 22 ft
lb)
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4-24
FRONT AND REAR BRAKESCHAS
Order Job / Part Q’ty Remarks
Disassembling the front brake
master cylinder
Brake master cylinder kit
Bleed screw
Brake master cylinder body1
1
1Disassemble the parts in the order listed.
For assembly, reverse the disassembly
procedure.
1
2
3
6 Nm (0.6 m
kg, 4.3 ft
lb)
EAS00585
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4-25
FRONT AND REAR BRAKESCHAS
Order Job / Part Q’ty Remarks
1
2
3
4
5
6
7
8
9
10
11Removing the rear brake master
cylinder
Brake fluid
Brake fluid reservoir cap
Brake fluid reservoir diaphragm holder
Brake fluid reservoir diaphragm
Brake fluid reservoir tank
Brake fluid reservoir hose
Hose joint
Bush
Union bolt
Copper washer
Brake hose
Brake master cylinder1
1
1
1
1
1
1
1
2
1
1Remove the parts in the order listed.
Drain.
Refer to “CHANGING THE BRAKE
FLUID” in chapter 3.
For installation, reverse the removal
procedure.
30 Nm (3.0 m
kg, 22 ft
lb)18 Nm (1.8 m
kg, 13 ft
lb)
EAS00586
REAR BRAKE MASTER CYLINDER
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4-26
FRONT AND REAR BRAKESCHAS
Order Job / Part Q’ty Remarks
Disassembling the rear brake master
cylinder
Brake master cylinder kit
Hose joint
Bush
Brake master cylinder body1
1
1
1Disassemble the parts in the order listed.
For assembly, reverse the disassembly
procedure.
1
2
3
4
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4-27
FRONT AND REAR BRAKESCHAS
NOTE:
NOTE:
NOTE:
EAS00588
DISASSEMBLING THE FRONT BRAKE
MASTER CYLINDER
Before disassembling the front brake master
cylinder, drain the brake fluid from the entire
brake system.
1. Disconnect:

brake light switch connector
1
(from the brake light switch)
2. Remove:

union bolt
2

copper washers 3

brake hose 4
To collect any remaining brake fluid, place a
container under the master cylinder and the end
of the brake hose.
3. Remove :

brake master cylinder bracket

brake master cylinder assembly
4. Remove :

dust boot

circlip
EAS00589
DISASSEMBLING THE REAR BRAKE
MASTER CYLINDER
1. Remove:

union bolt
1

copper washers 2

brake hose 3
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 assembly
3. Remove :

dust boot

circlip
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