2004 YAMAHA YZF-R1S Service Manual

4-30
FRONT AND REAR BRAKESCHAS
NOTE:
WARNING
CAUTION:

While holding the brake hose, tighten the
union bolt.

Turn the handlebars to the left and right to
make sure the brake hose does not touch oth-
er parts (e.g., wire harness, cables, leads).
Correct if necessary.
4. Fill:

brake fluid reservoir
(with the specified amount of the recom-
mended brake fluid)
Recommended brake fluid
DOT 4

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.

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.
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” in chapter 3.
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4-31
FRONT AND REAR BRAKESCHAS
30 Nm (3.0 m
kg, 22 ft
lb)
WARNING
CAUTION:
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 lever operation
Soft or spongy feeling
Bleed the brake
system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
EAS00608
ASSEMBLING THE REAR BRAKE MASTER
CYLINDER
1. Install:

brake master cylinder kit

circlip

dust boot
2. Install:

copper washers
New

brake hoses

union bolt
Proper brake hose routing is essential to in-
sure safe motorcycle operation. Refer to
“CABLE ROUTING”.
When installing the brake hose onto the
brake master cylinder, make sure the brake
pipe touches the projection
a as shown.
3. Fill:

brake fluid reservoir
(to the maximum level mark
b)
Recommended brake fluid
DOT 4
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4-32
FRONT AND REAR BRAKESCHAS
WARNING
CAUTION:

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.

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.
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.
4. Bleed:

brake system
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
5. 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.
6. Adjust:

rear brake light operation timing
Refer to “ADJUSTING THE REAR BRAKE
LIGHT SWITCH” in chapter 3.
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4-33
FRONT AND REAR BRAKESCHAS
Order Job / Part Q’ty Remarks
1
2
3
4Removing the front brake calipers
Brake fluid
Union bolt
Copper washer
brake hose
brake caliper1
2
1
1Remove the parts in the order listed.
The following procedure applies to both of
the front brake calipers.
Drain.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
For installation, reverse the removal
procedure.
NOTE:
6 Nm (0.6 m
kg, 4.3 ft
lb)
30 Nm (3.0 m
kg, 22 ft
lb)
35 Nm (3.5 m
kg, 25 ft
lb)
EAS00613
FRONT BRAKE CALIPERS
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4-34
FRONT AND REAR BRAKESCHAS
Order Job / Part Q’ty Remarks
Disassembling the front brake
calipers
Brake pad clip
Brake pad pin
Brake pad spring
Brake pad
Brake caliper piston
Brake caliper piston seal
Bleed screw2
1
1
2
4
8
1Disassemble the parts in the order listed.
The following procedure applies to both of
the front brake calipers.
For assembly, reverse the disassembly
procedure.
NOTE:
1
2
3
4
5
6
7
5 Nm (0.5 m
kg, 3.6 ft
lb)
EAS00615
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4-35
FRONT AND REAR BRAKESCHAS
Order Job / Part Q’ty Remarks
1
2
3
4Removing the rear brake caliper
Brake fluid
Union bolt
Copper washer
Brake hose
Brake caliper1
2
1
1Remove the parts in the order listed.
Drain.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
For installation, reverse the removal
procedure.
30 Nm (3.0 m
kg, 22 ft
lb)
27 Nm (2.7 m
kg, 20 ft
lb)22 Nm (2.2 m
kg, 16 ft
lb)
EAS00616
REAR BRAKE CALIPER
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4-36
FRONT AND REAR BRAKESCHAS
Order Job / Part Q’ty Remarks
Disassembling the rear brake caliper
Screw plug
Brake pad pin
Brake pad
Brake pad shim
Brake pad spring
Brake caliper piston
Brake caliper piston seal
Bleed screw1
1
2
4
1
1
2
1Disassemble the parts in the order listed.
For assembly, reverse the disassembly
procedure.
1
2
3
4
5
6
7
8
5 Nm (0.5 m
kg, 3.6 ft
lb)
17 Nm (1.7 m
kg, 12 ft
lb)
3 Nm (0.3 m
kg, 2.2 ft
lb)
EAS00617
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4-37
FRONT AND REAR BRAKESCHAS
NOTE:
NOTE:
WARNING
EAS00625
DISASSEMBLING THE FRONT BRAKE
CALIPERS
The following procedure applies to both of the
brake calipers.
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
Put the end of the brake hose into a container
and pump out the brake fluid carefully.
2. Remove:

brake caliper pistons
1

brake caliper piston seals 2
a. Secure the 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 pis-
tons from the brake caliper.

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.
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