2004 YAMAHA YZF-R1S boot

2-35
CABLE ROUTINGSPEC
G Clamp the head light lead by
wrapping and insert it to the in-
take air grill hole. (only at the
right side.)
H Do not connect the wire to the
coupler with the plug for options.
I To the turn signal light
J To the wire harness
K Cut the tip of the clamp.A Insert to the rib of the head light.
(Either location of the right and
left relays is acceptable.)
B The lead should not stretch too
much.
C Make sure to insert the coupler
and boot to the stay 1 hole.
D The speedometer lead should
not be strained.
E To the stay 1 hole
F Connect after passing over the
upper side of the duct.1Ground lead
2Meter lead
3Stay 1
4Auxiliary light lead (right)
5Headlight lead
6Auxiliary light lead (left)
7Console panel 1
8Duct 1
9Console panel 2
10Duct 2
11Headlight lead (right)
12Headlight lead (left)
EAS00035
CABLE ROUTING
ProCarManuals.com

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
ProCarManuals.com

4-29
FRONT AND REAR BRAKESCHAS
WARNING
13 Nm (1.3 m
kg, 9.4 ft
lb)
NOTE:
30 Nm (3.0 m
kg, 22 ft
lb)
WARNING
EAS00607
ASSEMBLING AND INSTALLING THE
FRONT BRAKE MASTER CYLINDER

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.
Recommended brake fluid
DOT 4
1. Install :

brake master cylinder kit

circlip
New

dust boot
2. Install:

brake master cylinder
1

Install the brake master cylinder holder with
the “UP” mark
a facing up.

Align the end of the brake master cylinder
holder with the punch mark
b on the right han-
dlebar.

First, tighten the upper bolt, then the lower bolt.
There should be 2
2.5 mm (0.08
0.10 in)
for clearance between the right handlebar
switch and the brake master cylinder holder.
3. Install:

copper washers
New

brake hose

union bolt

brake light switch coupler
Proper brake hose routing is essential to in-
sure safe motorcycle operation. Refer to
“CABLE ROUTING”.
ProCarManuals.com

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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