2004 YAMAHA YZF-R1S Service Manual

4-38
FRONT AND REAR BRAKESCHAS
NOTE:
NOTE:
WARNING
EAS00626
DISASSEMBLING THE REAR BRAKE
CALIPER
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
Put the end of the brake hose into a container
and pump out the brake fluid carefully.
2. 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.

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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4-39
A
B
FRONT AND REAR BRAKESCHAS
WARNING
EAS00633
CHECKING THE FRONT AND REAR BRAKE
CALIPERS
Recommended brake component
p
replacement schedule
Brake padsIf necessary
Piston sealsEvery two years
Brake hosesEvery four years
Brake fluidEvery two years
and whenever the
brake is disas-
sembled
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.
Whenever a brake caliper is disassembled,
replace the brake caliper piston seals.
AFront
BRear
2. Check:

brake caliper bracket
1
Cracks / damage
Replace.
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4-40
FRONT AND REAR BRAKESCHAS
WARNING
35 Nm (3.5 m
kg, 25 ft
lb)
30 Nm (3.0 m
kg, 22 ft
lb)
6 Nm (0.6 m
kg, 4.3 ft
lb)
WARNING
CAUTION:
EAS00640
ASSEMBLING AND INSTALLING THE
FRONT BRAKE CALIPERS
The following procedure applies to both of the
brake calipers.

Before installation, all internal brake com-
ponents should be cleaned and lubricated
with clean or new brake fluid.

Never use solvents on internal brake com-
ponents as they will cause the piston seals
to swell and distort.

Whenever a brake caliper is disassembled,
replace the brake caliper piston seals.
Recommended brake fluid
DOT 4
1. Install :

brake pads

brake pad spring

brake pad pin
2. Install:

brake caliper
1

copper washers New

brake hose
2

union bolt 3

brake hose holder
Proper brake hose routing is essential to in-
sure safe motorcycle operation. Refer to
“CABLE ROUTING”.
When installing the brake hose onto the
brake caliper
1, make sure the brake pipe a
touches the projection b on the brake cali-
per.
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4-41
FRONT AND REAR BRAKESCHAS
WARNING
CAUTION:
3. 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.
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. Check:

brake lever operation
Soft or spongy feeling
Bleed the brake
system.
Refer to ”BLEEDING THE HYDRAULIC
BRAKE SYSTEM“ in chapter 3.
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4-42
FRONT AND REAR BRAKESCHAS
WARNING
27 Nm (2.7 m
kg, 20 ft
lb)
22 Nm (2.2 m
kg, 16 ft
lb)
30 Nm (3.0 m
kg, 22 ft
lb)
WARNING
CAUTION:
EAS00642
ASSEMBLING AND INSTALLING THE REAR
BRAKE CALIPER

Before installation, all internal brake com-
ponents should be cleaned and lubricated
with clean or new brake fluid.

Never use solvents on internal brake com-
ponents as they will cause the piston seals
to swell and distort.

Whenever a brake caliper is disassembled,
replace the brake caliper piston seals.
Recommended brake fluid
DOT 4
1. Install:

brake caliper
1
(front)
(rear)

brake pad pin

screw plug

copper washers
New

brake hose
2

union bolt 3
Proper brake hose routing is essential to in-
sure safe motorcycle operation. Refer to
“CABLE ROUTING”.
When installing the brake hose onto the
brake caliper
1, make sure the brake pipe a
touches the projection b on the brake cali-
per.
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4-43
FRONT AND REAR BRAKESCHAS
WARNING
CAUTION:
2. 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.
3. Bleed:

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

brake pedal operation
Soft or spongy feeling
Bleed the brake
system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
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4-44
Order Job / Part Q’ty Remarks
1
2
3
4
5
6Removing the front fork legs
Front wheel
Front brake calipers
Side cowlings
Front fender
Cap bolt
Handlebar pinch bolt
Upper bracket pinch bolt
Under bracket pinch bolt
Front fork leg1
1
1
1
2
1Remove the parts in the order listed.
Refer to “FRONT WHEEL AND BRAKE
DISCS”.
Refer to “FRONT AND REAR BRAKES”.
Refer to “COWLINGS” in chapter3.
Loosen.
Loosen.
Loosen.
Loosen.
For installation, reverse the removal
procedure.
6 Nm (0.6 m
kg, 4.3 ft
lb)
23 Nm (2.3 m
kg, 17 ft
lb)
17 Nm (1.7 m
kg, 12 ft
lb)
26 Nm (2.6 m
kg, 19 ft
lb)
23 Nm (2.3 m
kg, 17 ft
lb)
FRONT FORKCHAS
EAS00647
FRONT FORK
FRONT FORK LEGS
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4-45
FRONT FORKCHAS
Order Job / Part Q’ty Remarks
Disassembling the front fork legs
Cap bolt
O-ring
Damper adjusting rod
Nut
Washer
Spacer
Fork spring
Dust seal
Oil seal clip
Oil seal1
1
1
1
1
1
1
1
1
1Disassemble the parts in the order listed.
The following the procedure applies to
both of the front fork legs.
NOTE:
1
2
3
4
5
6
7
8
9
10
23 Nm (2.3 m
kg, 17 ft
lb)
15 Nm (1.5 m
kg, 11 ft
lb)
23 Nm (2.3 m
kg, 17 ft
lb)
EAS00648
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