2004 YAMAHA YZF-R1S brake

3-8
Order Job / Part Q’ty Remarks
1
2
3
4
5
6Removing the rear cowling
Rider seat and passenger seat
Muffler
Rear cowling (upper)
Tail / brake light lead coupler
Rear turn signal light lead coupler
Tail / brake light
License plate bracket assembly
Rear cowling (lower)1
1
4
1
1
1Remove the parts in the order listed.
Refer to “SEATS”.
Refer to “EXHAUST PIPE” in chapter 5.
Disconnect.
Disconnect.
For installation, reverse the removal
procedure.
4 Nm (0.4 m
kg, 2.9 ft
lb)10 Nm (1.0 m
kg, 7.2 ft
lb)
COWLINGS
CHK
ADJ
REAR COWLING
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3-42
ADJUSTING THE FRONT BRAKE
CHK
ADJ
NOTE:
a
ac
b
WARNING
CAUTION:
EAS00107
CHASSIS
ADJUSTING THE FRONT BRAKE
1. Adjust:

brake lever position
(distance
a from the throttle grip to the brake
lever)
While pushing the brake lever forward, turn the
adjusting dial
1 until the brake lever is in the de-
sired position.
Direction
Distance is the
largest.
DirectionDistance is the
smallest.

After adjusting the brake lever position,
make sure the pin on the brake lever holder
is firmly inserted in the hole in the adjust-
ing dial.

A soft or spongy feeling in the brake lever
can indicate the presence of air in the brake
system. Before the vehicle is operated, the
air must be removed by bleeding the brake
system. Air in the brake system will consid-
erably reduce in loss of control and possi-
bly an accident. Therefore, check and if
necessary, bleed the brake system.
After adjusting the brake lever position,
make sure there is no brake drag.
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3-43
ADJUSTING THE REAR BRAKE
CHK
ADJ
a
b
WARNING
WARNING
CAUTION:
EAS00110
ADJUSTING THE REAR BRAKE
1. Adjust:

brake pedal position
a. Loosen the locknut
1.
b. Turn the adjusting bolt
2 in direction a or b
until the specified brake pedal position is ob-
tained.
Direction
Brake pedal is raised.
DirectionBrake pedal is lowered.
After adjusting the brake pedal position,
check that the end of the adjusting bolt
c is
visible through the hole
d.
c. Tighten the locknut
1 to specification.
Locknut
16 Nm (1.6 m
kg, 12 ft
lb)
A soft or spongy feeling in the brake pedal
can indicate the presence of air in the brake
system. Before the vehicle is operated, the
air must be removed by bleeding the brake
system. Air in the brake system will consid-
erably reduce braking performance and
could result in loss of control and possibly
an accident. Therefore, check and, if neces-
sary, bleed the brake system.
After adjusting the brake pedal position,
make sure there is no brake drag.
2. Adjust:

rear brake light switch
Refer to “ADJUSTING THE REAR BRAKE
LIGHT SWITCH”.
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3-44
A
B
CHECKING THE BRAKE FLUID LEVEL
CHK
ADJ
NOTE:
WARNING
CAUTION:
NOTE:
EAS00115
CHECKING THE BRAKE FLUID LEVEL
1. Stand the motorcycle on a level surface.

Place the motorcycle on a suitable stand.

Make sure the motorcycle is upright.
2. Check:

brake fluid level
Below the minimum level mark
a
Add the
recommended brake fluid to the proper level.
Recommended brake fluid
DOT 4
AFront brake
BRear brake

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.
In order to ensure a correct reading of the brake
fluid level, make sure the top of the brake fluid
reservoir is horizontal.
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3-45
ADJUSTING THE REAR BRAKE LIGHT SWITCH /
CHECKING THE FRONT AND REAR BRAKE PADSCHK
ADJ
NOTE:
a
b
EAS00128
ADJUSTING THE REAR BRAKE LIGHT
SWITCH
The rear brake light switch is operated by move-
ment of the brake pedal.
The rear brake light switch is properly adjusted
when the brake light comes on just before the
braking effect starts.
1. Check:

rear brake light operation timing
Incorrect
Adjust.
2. Adjust:

rear brake light operation timing
a. Hold the main body
1 of the rear brake light
switch so that it does not rotate and turn the
adjusting nut
2 in direction a or b until the
rear brake light comes on at the proper time.
Direction
Brake light comes on
sooner.
DirectionBrake light comes on
later.
EAS00122
CHECKING THE FRONT AND REAR BRAKE
PADS
The following procedure applies to all of the
brake pads.
1. Operate the brake.
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3-46
B
A
B
A
CHECKING THE FRONT AND REAR BRAKE PADS
/
CHECKING THE FRONT AND REAR BRAKE HOSESCHK
ADJ
2. Check:

front brake pad

rear brake pad
Brake pad wear limit
a, b
Wear limit reached
Replace the brake
pads as a set.
Refer to “FRONT AND REAR BRAKES” in
chapter 7.
Brake pad wear limit
a 0.5 mm (0.02 in)
b 1.0 mm (0.04 in)
AFront brake
BRear brake
EAS00131
CHECKING THE FRONT AND REAR BRAKE
HOSES
The following procedure applies to all of the
brake hoses and brake hose clamps.
1. Check:

brake hose
1
Cracks / damage / wear
Replace.
AFront
BRear
2. Check:

brake hose clamp
2
Loose
Tighten the clamp bolt.
3. Hold the motorcycle upright and apply the
brake several times.
4. Check:

brake hose
Brake fluid leakage
Replace the damaged
hose.
Refer to “FRONT AND REAR BRAKES” in
chapter 4.
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3-47
B
C
A
BLEEDING THE HYDRAULIC BRAKE SYSTEM
CHK
ADJ
WARNING
NOTE:
NOTE:
EAS00135
BLEEDING THE HYDRAULIC BRAKE
SYSTEM
Bleed the hydraulic brake system whenev-
er:

the system is disassembled.

a brake hose is loosened, disconnected or
replaced.

the brake fluid level is very low.

brake operation is faulty.

Be careful not to spill any brake fluid or allow
the brake fluid reservoir to overflow.

When bleeding the hydraulic brake system,
make sure there is always enough brake fluid
before applying the brake. Ignoring this pre-
caution could allow air to enter the hydraulic
brake system, considerably lengthening the
bleeding procedure.

If bleeding is difficult, it may be necessary to let
the brake fluid settle for a few hours. Repeat
the bleeding procedure when the tiny bubbles
in the hose have disappeared.
1. Bleed:

hydraulic brake system
a. Fill the brake fluid reservoir to the proper lev-
el with the recommended brake fluid.
b. Install the brake fluid reservoir diaphragm.
c. Connect a clear plastic hose
1 tightly to the
bleed screw
2.
AFront brake master cylinder
BFront brake caliper
CRear brake caliper
Bleeding order of the front hydraulic brake sys-
tem is the following order:
1. front brake master cylinder.
2. front brake calipers.
3. front brake master cylinder.
d. Place the other end of the hose into a con-
tainer.
e. Slowly apply the brake several times.
f. Fully pull the brake lever or fully press down
the brake pedal and hold it in position.
g. Loosen the bleed screw.
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3-48
BLEEDING THE HYDRAULIC BRAKE SYSTEM /
ADJUSTING THE SHIFT PEDALCHK
ADJ
NOTE:
WARNING
NOTE:
a
b
Loosening the bleed screw will release the pres-
sure and cause the brake lever to contact the
throttle grip or the brake pedal to fully extend.
h. Tighten the bleed screw and then release the
brake lever or brake pedal.
i. Repeat steps (e) to (h) until all of the air
bubbles have disappeared from the brake
fluid in the plastic hose.
j. Tighten the bleed screw to specification.
Bleed screw
6 Nm (0.6 m
kg, 4.3 ft
lb)
k. Fill the brake fluid reservoir to the proper lev-
el with the recommended brake fluid.
Refer to “CHECKING THE BRAKE FLUID
LEVEL”.
After bleeding the hydraulic brake system,
check the brake operation.
After bleeding air, the brake fluid may ooze
around the thread section of each bleed screw.
This phenomenon does not show the leakage
but the brake fluid that has been accumulated in
the thread of screw while bleeding air. Please
wipe off to make the parts clean.
EAS00136
ADJUSTING THE SHIFT PEDAL
1. Adjust:

shift pedal position
a. Loosen both locknuts
1.
b. Turn the shift rod
2 in direction a or b to
obtain the correct shift pedal position.
Direction
Shift pedal is raised.
DirectionShift pedal is lowered.
c. Tighten both locknuts.
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